Color filter manufacturing method, color filter, image display device, and electronic device

ABSTRACT

A color filter manufacturing method includes discharging droplets of an ink from a droplet discharge head into a plurality of cells formed on a substrate while moving the substrate with respect to the droplet discharge head, and curing the ink discharged in the cells to form a colored portion within each of the cells. The discharging of the droplets includes prohibiting landing of the droplets in a landing prohibition region formed at a predetermined width from edges of each of the cells in a movement direction of the substrate with respect to the droplet discharge head. The landing prohibition region being arranged so that a relationship 0.5≦L 1 /L 2 ≦4.5 is satisfied, wherein a value L 1  indicates a width of the landing prohibition region and a value L 2  indicates an average diameter of the droplets of the ink.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Japanese Patent Application No.2008-008816 filed on Jan. 18, 2008. The entire disclosure of JapanesePatent Application No. 2008-008816 is hereby incorporated herein byreference.

BACKGROUND

1. Technical Field

The present invention relates to a color filter manufacturing method, acolor filter, an image display device, and an electronic device.

2. Related Art

Color filters are generally used in liquid crystal display devices (LCD)and the like that display color.

Color filters have conventionally been manufactured using a so-calledphotolithography method in which a coating film composed of a material(color layer formation composition) that includes a colorant, aphotosensitive resin, a functional monomer, a polymerization initiator,and other components is formed on a substrate, and then photosensitiveprocessing for radiating light via a photomask, development processing,and the like are performed. In such a method, the color filters areusually manufactured by repeating a process in which a coating filmcorresponding to each color is formed on substantially the entiresurface of the substrate, only a portion of the coating film is cured,and most of the film other than the cured portion is removed, so thatthere is no color overlap. Therefore, only a portion of the coating filmformed in color filter manufacturing remains as a color layer in thefinished color filter, and most of the coating film is removed in themanufacturing process. Therefore, not only does the manufacturing costof the color filter increase, but the process is also undesirable fromthe perspective of resource saving.

Methods have recently been proposed for forming the color layer of acolor filter by using an inkjet head (droplet discharge head) todischarge a material (color layer formation ink; hereinafter referred toas ink) for forming a color layer in a plurality of cells provided on asubstrate (see Japanese Laid-Open Patent Application No. 2002-372613,for example). In such a method, because the discharge position and thelike of the ink droplets are easily controlled, and waste of the colorlayer formation composition can be reduced, the environmental impact canbe reduced, and manufacturing cost can also be minimized.

The ink used to manufacture the color filter includes a colorant, aresin material, and other components. Therefore, such an ink usually hasa high viscosity. In manufacturing the color filter, the ink is usuallydischarged while the substrate is moved relative to the inkjet head forthe sake of productivity.

When an ink having such a relatively high viscosity is discharged,trailing can sometimes occur. Depending on the landing position of theink, the trail portion (hereinafter referred to as the satellite) isrecovered within the same cell when the trailing breaks off, but thesatellite sometimes enters an adjacent cell in conjunction with therelative movement of the substrate, and the problem of mixing betweenadjacent cells thereby occurs. As a result, a color layer having thedesired coloration cannot be formed, and the color reproductionproperties of the manufactured color filter are adversely affected. Thecell height and shape may be designed so as to prevent such mixing, butwhen the height of the cells is increased, a large amount of ink must bedischarged, the thickness of the color layer increases, and theproductivity and light usage efficiency are reduced. The problem ofcolor mixing such as described above is severe when the frequency ofdischarge from the inkjet head is increased, and the speed of relativemovement of the substrate is increased in order to enhance productivity.

SUMMARY

An object of the present invention is to provide a method formanufacturing a color filter which has excellent color reproductionproperties and in which color mixing is prevented, to provide a colorfilter having excellent color reproduction properties, and to provide animage display device and electronic device that are provided with thecolor filter.

Such objects are achieved by the present invention describedhereinafter.

A color filter manufacturing method according to a first aspect includesdischarging droplets of an ink from a droplet discharge head into aplurality of cells formed on a substrate while moving the substrate withrespect to the droplet discharge head, and curing the ink discharged inthe cells to form a colored portion within each of the cells. Thedischarging of the droplets includes prohibiting landing of the dropletsin a landing prohibition region formed at a predetermined width fromedges of each of the cells in a movement direction of the substrate withrespect to the droplet discharge head. The landing prohibition regionbeing arranged so that a relationship 0.5≦L₁/L₂≦4.5 is satisfied,wherein a value L₁ (μm) indicates a width of the landing prohibitionregion and a value L₂ (μm) indicates an average diameter of the dropletsof the ink.

It is thereby possible to provide a method for manufacturing a colorfilter which has excellent color reproduction properties and in whichcolor mixing is prevented.

In the color filter manufacturing method as described above, the landingprohibition region is preferably arranged such that a relationship0.025≦L₁/L₃≦0.5 is satisfied, wherein a value L₃ (μm) indicates a widthof each of the cells in the movement direction of the substrate withrespect to the droplet discharge head.

Color mixing of the colored portions (inks) between adjacent cells canthereby be more effectively prevented.

In the color filter manufacturing method as described above, the widthL₁ of the landing prohibition region is preferably 3.0 to 50.0 μm.

Color mixing of the colored portions (inks) between adjacent cells canthereby be more effectively prevented.

In the color filter manufacturing method as described above, the inkpreferably has a viscosity of 13 mPa·s or less at 25° C.

The ink can thereby be more reliably spread into the cells, while colormixing of the colored portions (inks) between adjacent cells iseffectively prevented.

In the color filter manufacturing method as described above, thedroplets preferably have a contact angle of 60° or less with respect tothe substrate.

The ink can thereby be more reliably spread into the cells, while colormixing of the colored portions (inks) between adjacent cells iseffectively prevented.

In the color filter manufacturing method as described above, thedischarging of the droplets preferably includes moving the substratewith respect to the droplet discharge head at a speed of 30 to 400mm/second.

Color mixing of the colored portions (inks) between adjacent cells canthereby be more effectively prevented.

In the color filter manufacturing method as described above, thesubstrate preferably includes a partition wall provided between anadjacent pair of the cells with the partition wall having a height of1.4 to 2.6 μm.

Color mixing of the colored portions (inks) between adjacent cells canthereby be more effectively prevented.

In the color filter manufacturing method as described above, the inkpreferably includes at least a colorant, a resin material, and a solventwith the resin material including a first polymer containing at least afirst epoxy-containing vinyl monomer as a monomer component.

The discharge stability of the ink can thereby be enhanced, and colormixing of the colored portions (inks) between adjacent cells can be moreeffectively prevented.

In the color filter manufacturing method as described above, the firstpolymer is preferably a copolymer having the first epoxy-containingvinyl monomer and a second vinyl monomer as monomer components, thesecond vinyl monomer having an isocyanate group or a block isocyanategroup in which an isocyanate group is protected by a protective group.

The discharge stability of the ink can thereby be enhanced, and colormixing of the colored portions (inks) between adjacent cells can be moreeffectively prevented.

In the color filter manufacturing method as described above, the firstpolymer is preferably a copolymer having the first epoxy-containingvinyl monomer and a third vinyl monomer as monomer components, the thirdvinyl monomer having a hydroxyl group.

The discharge stability of the ink can thereby be enhanced, and colormixing of the colored portions (inks) between adjacent cells can be moreeffectively prevented.

In the color filter manufacturing method as described above, the resinmaterial preferably further includes a second polymer containing atleast an alkoxysilyl-containing vinyl monomer represented by Formula (1)below as a monomer component.

In Formula (1), R¹ represents a hydrogen atom or a C₁₋₇ alkyl group, Erepresents a single bond hydrocarbon group or a bivalent hydrocarbongroup, R² represents a C₁₋₆ alkyl group or a C₁₋₆ alkoxyl group, R³represents a C₁₋₆ alkyl group or a C₁₋₆ alkoxyl group, R⁴ represents aC₁₋₆ alkyl group, a value x is 0 or 1, and a value y is an integer from1 to 10.

The ink can thereby be provided with a satisfactory viscosity, and theink can be more reliably spread into the entire area of the cells, whilecolor mixing of the colored portions (inks) between adjacent cells iseffectively prevented. Adhesion between the substrate and the coloredportion is also enhanced.

In the color filter manufacturing method as described above, the resinmaterial when uncured preferably further includes a third polymercontaining at least a fluoroalkyl- or fluoroaryl-containing vinylmonomer represented by a chemical formula (2) below as a monomercomponent.

In Formula (2), R⁵ represents a hydrogen atom or a C₁₋₇ alkyl group, Drepresents a single bond hydrocarbon group, a bivalent hydrocarbongroup, or a bivalent hydrocarbon group containing a hetero atom, Rfrepresents a C₁₋₂₀ fluoroalkyl group or fluoroaryl group, and a value zis 0 or 1.

The discharge stability of the ink can thereby be enhanced, and colormixing of the colored portions (inks) between adjacent cells can be moreeffectively prevented.

A color filter according to a second aspect is manufactured using thecolor filter manufacturing method as described above.

It is thereby possible to provide a color filter which has excellentcolor reproduction properties and in which color mixing is prevented.

An image display device according to a third aspect has the color filteras described above.

An image display device can thereby be provided that is capable of imagedisplay having excellent color reproduction properties.

An electronic device according to a fourth aspect has the image displaydevice as described above.

An electronic device can thereby be provided that is capable of imagedisplay having excellent color reproduction properties.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of thisoriginal disclosure:

FIG. 1 is a cross-sectional view showing a preferred embodiment of acolor filter according to the present invention.

FIG. 2 includes a series of cross-sectional views (1 a) to (1 e) showinga method for manufacturing a color filter.

FIG. 3 is perspective view showing a droplet discharge device used inthe manufacture of the color filter.

FIG. 4 is a view of the droplet discharge means of the droplet dischargedevice shown in FIG. 3 as seen from the stage.

FIG. 5 is a view showing the bottom surface of the droplet dischargehead of the droplet discharge device shown in FIG. 3.

FIG. 6 includes a pair of diagrams (a) and (b) showing a dropletdischarge head of the droplet discharge device shown in FIG. 3, whereinFIG. 6( a) is a cross-sectional perspective view and FIG. 6( b) is across-sectional view.

FIG. 7 is an enlarged plan view of a cell formed on the substrate.

FIG. 8 is a cross-sectional view showing an embodiment of a liquidcrystal display device.

FIG. 9 is a perspective view showing a mobile (or notebook) personalcomputer exemplifying an electronic device in accordance with thepresent invention.

FIG. 10 is a perspective view showing a portable telephone (includingPHS) exemplifying an electronic device in accordance with the presentinvention.

FIG. 11 is a perspective view showing a digital still cameraexemplifying an electronic device in accordance with the presentinvention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Preferred embodiments of the present invention will be described indetail hereinafter.

Color Filter

An example of the color filter of the present invention will first bedescribed.

FIG. 1 is a sectional view showing a preferred embodiment of the colorfilter of the present invention.

A color filter 1 is provided with a substrate 11 and colored portions 12formed using the color filter ink described above, as shown in FIG. 1.The colored portions 12 are provided with a first colored portion 12A, asecond colored portion 12B, and a third colored portion 12C, havingmutually different colors. A partition wall 13 is disposed betweenadjacent colored portions 12.

Substrate

The substrate 11 is a plate-shaped member having optical transparency,and has a function for holding the colored portions 12 and the partitionwall 13.

It is preferred that the substrate 11 be essentially composed of atransparent material. A clearer image can thereby be formed by lighttransmitted through the color filter 1.

The substrate 11 is preferably one having excellent heat resistance andmechanical strength. Deformations or the like caused by, e.g., heatapplied during the manufacture of the color filter 1 can thereby bereliably prevented. Examples of a constituent material of the substrate11 that satisfies such conditions include glass, silicon, polycarbonate,polyester, aromatic polyamide, polyamidoimide, polyimide,norbornene-based ring-opening polymers, and hydrogenated substances.

Colored Portions

The colored portions 12 are formed using a color filter ink set such asthat described above.

The colored portions 12 are formed using a color filter ink set such asthat described above, and therefore have little variation incharacteristics between pixels, and unintentional color mixing (mixingof a plurality of color filter inks) and the like is reliably prevented.For this reason, the color filter 1 is highly reliable in that theoccurrence of unevenness of color and saturation, and the like isreduced. The color filter 1 also has excellent contrast and excellentcoloration properties of the colored portions 12.

Each colored portion 12 is disposed inside a cell 14, which is an areaenclosed by a later-described partition wall 13.

The first colored portion 12A, the second colored portion 12B, and thethird colored portion 12C have mutually different colors. For example,the first colored portion 12A can be a red filter area (R), secondcolored portion 12B can be a green filter area (G), and the thirdcolored portion 12C can be a blue filter area (B). The colored portions12A, 12B, 12C as a single set of different colors constitute a singlepixel. A prescribed number of the colored portions 12 are disposed inthe lateral and longitudinal directions in the color filter 1. Forexample, when the color filter 1 is a color filter for high definition,1366×768 pixels are disposed; when the color filter is a color filterfor full high definition, 1920×1080 pixels are disposed; and when thecolor filter is a color filter for super high definition, 7680×4320pixels are disposed. The color filter 1 may be provided with, e.g.,spare pixels outside of the effective area.

Partition Wall

A partition wall (bank) 13 is disposed between adjacent colored portions12. Adjacent colored portions 12 can thereby be reliably prevented fromcolor mixing, and as a result, a sharp image can be reliably displayed.

The partition wall 13 may be composed of a transparent material, but ispreferably composed of material having light-blocking properties. Animage with excellent contrast can thereby be displayed. The color of thepartition wall (light-blocking portion) 13 is not particularly limited,but black is preferred. Accordingly, the contrast of a displayed imageis particularly good.

The height of the partition wall 13 is preferably 1.4 to 2.6 μm, andmore preferably 1.6 to 2.5 μm. Color mixing (ink color mixing) betweenadjacent colored portions 12 can thereby be reliably prevented. Imagedisplay devices and electronic devices provided with the color filter 1can also be provided with excellent visual angle characteristics. Theheight of a partition wall 13 is the height from the bottom of theinside of a cell 14 to the top of the partition wall 13.

The partition wall 13 may be composed of any material, but is preferablycomposed principally of a resin material, for example. Accordingly, apartition wall 13 having a desired shape can be easily formed using amethod described hereinafter. In the case that the partition wall 13functions as a light-blocking portion, carbon black or anotherlight-absorbing material may be included as a constituent element of thepartition wall.

Method for Manufacturing Color Filter

Next, an example of the method for manufacturing the color filter willbe described.

FIG. 2 is a cross-sectional view showing a method for manufacturing acolor filter; FIG. 3 is a perspective view showing the droplet dischargedevice used in the manufacture of the color filter; FIG. 4 is a view ofdroplet discharge means in the droplet discharge device shown in FIG. 3,as seen from the stage side; FIG. 5 is a view showing the bottom surfaceof the droplet discharge head in the droplet discharge device shown inFIG. 3; FIG. 6 is a view showing the droplet discharge head in thedroplet discharge device shown in FIG. 3, wherein FIG. 6( a) is across-sectional perspective view and FIG. 6( b) is a cross-sectionalview; and FIG. 7 is an enlarged plan view showing a cell formed on thesubstrate.

The color filter manufacturing method of the present invention has anink application step of applying droplets of ink used to form coloredportions (hereinafter referred to simply as “ink”) from a dropletdischarge head in a cell while moving a substrate, to which numerouscells are provided, in relation to the droplet discharge head; and acolored portion formation step of curing the ink applied in the cell toform a colored portion.

As shown in FIG. 2, the color filter manufacturing method in the presentembodiment has a substrate preparation step (1 a) of preparing thesubstrate 11, a partition wall formation step (1 b, 1 c) of forming apartition wall 13 on the substrate 11, an ink application step (1 d) ofmoving the substrate 11 in relation to the droplet discharge head andapplying the ink 2 by an inkjet method in a region (cell) 14 surroundedby the partition wall 13, and a colored portion formation step (1 e) ofremoving the solvent from the ink 2 and then curing to form a coloredportion 12.

Each step will be described in detail below.

Substrate Preparation Step

First, a substrate 11 is prepared (1 a). It is preferred that thesubstrate 11 to be prepared in the present step undergo a washingtreatment. The substrate 11 to be prepared in the present step may bewashed by chemical treatment using a silane-coupling agent or the like,a plasma treatment, ion plating, sputtering, gas phase reaction, vacuumdeposition, or another suitable washing treatment.

Partition Wall Formation Step

Next, a radiation-sensitive composition for forming the partition wallof the substrate 11 is applied to substantially the entire surface ofone of the surfaces of the substrate 11 to form (1 b) a coated film 3. Aprebaking treatment may be performed as required after theradiation-sensitive composition has been applied to the substrate 11.The prebaking treatment may be carried out under the conditions of,e.g., a heating temperature of 50 to 150° C. and a heating time of 30 to600 seconds.

Next, a partition wall 13 is formed (1 c) by irradiating the surface viaa photomask, performing a post exposure bake (PEB), and carrying out adevelopment treatment using an alkali development fluid. PEB can becarried out under the following example conditions: a heatingtemperature of 50 to 150° C., a heating time of 30 to 600 seconds, and aradiation intensity of 1 to 500 mJ/cm². The development treatment can beperformed using, e.g., fluid overflow, dipping, vibration soaking, oranother method, and the development treatment time can be set to 10 to300 seconds, for example. After the development treatment, a post bakingtreatment may be performed as required. The post baking treatment can becarried out under the following example conditions: a heatingtemperature of 150 to 280° C. and a heating time of 3 to 120 minutes.

Ink Application Step

Next, the ink 2 is applied (1 d) to the cells 14 surrounded by thepartition wall 13 using the inkjet method.

The present step is carried out using a color filter ink set providedwith a plurality of types of inks 2 that correspond to the plurality ofcolors of the colored portions 12 to be formed.

In the present embodiment, discharge of the ink 2 is performed using adroplet discharge device such as that shown in FIGS. 3 through 6.

The droplet discharge device 100 used in the present step is providedwith a tank 101 for holding the ink 2, a tube 110, and a discharge scanunit 102 to which the ink 2 is fed from the tank 101 via the tube 110,as shown in FIG. 3. The discharge scan unit 102 is provided with dropletdischarge means 103 in which a plurality of droplet discharge heads(inkjet heads) 114 is mounted on a carriage 105, a first positioncontroller 104 (movement means) for controlling the position of thedroplet discharge means 103, a stage 106 for holding the substrate 11(hereinafter simply referred to as “substrate 11”) on which thepartition wall 13 is formed in an aforementioned step, a second positioncontroller 108 (movement means) for controlling the position of thestage 106, and control means 112. The tank 101 and the plurality ofdroplet discharge heads 114 in the droplet discharge means 103 areconnected by the tube 110, and the ink 2 is fed by compressed air fromthe tank 101 to each of the plurality of droplet discharge heads 114.

The first position controller 104 moves the droplet discharge means 103along the X-axis direction and Z-axis direction orthogonal to the X-axisdirection, in accordance with a signal from the control means 112. Thefirst position controller 104 also has a function for rotating thedroplet discharge means 103 about the axis parallel to the Z-axis. Inthe present embodiment, the Z-axis direction is the direction parallelto the perpendicular direction (i.e., the direction of gravitationalacceleration). The second position controller 108 moves the stage 106along the Y-axis direction, which is orthogonal to both the X-axisdirection and the Z-axis direction, in accordance with a signal from thecontrol means 112. The second position controller 108 also has afunction for rotating the stage 106 about the axis parallel to theZ-axis.

The stage 106 has a surface parallel to both the X-axis direction andthe Y-axis direction. The stage 106 is configured so as to be capable ofsecuring or holding the substrate 11 on the planar surface thereof, thesubstrate having the cells 14 in which the ink 2 is to be applied.

As described above, the droplet discharge means 103 is moved in theX-axis direction by the first position controller 104. On the otherhand, the stage 106 is moved in the Y-axis direction by the secondposition controller 108. In other words, the relative position of thedroplet discharge heads 114 in relation to the stage 106 is changed bythe first position controller 104 and the second position controller108. In other words, the substrate 11 held on the stage 106 and thedroplet discharge means 103 move in a relative fashion. In the presentinvention, the ink is applied to the substrate while the substrate ismoved in this manner in relation to the droplet discharge means (dropletdischarge head).

The control means 112 is configured so as to receive from an externalinformation processor discharge data that express the relative positionin which the ink 2 is to be discharged.

The droplet discharge means 103 has a plurality of droplet dischargeheads 114, which have substantially the same structure as each other,and a carriage 105 for holding the droplet discharge heads 114, as shownin FIG. 4. In the present embodiment, the number of droplet dischargeheads 114 held in the droplet discharge means 103 is eight. Each of thedroplet discharge heads 114 has a bottom surface on which a plurality oflater-described nozzles 118 is disposed. The shape of the bottom surfaceof each of the droplet discharge heads 114 is a polygon having two shortsides and two long sides. The bottom surface of the droplet dischargeheads 114 held in the droplet discharge means 103 faces the stage 106side, and the long-side direction and the short-side direction of thedroplet discharge heads 114 are parallel to the X-axis direction and theY-axis direction, respectively.

The droplet discharge heads 114 have a plurality of nozzles 118 alignedin the X-axis direction, as shown in FIG. 5. The plurality of nozzles118 is disposed so that a nozzle pitch HXP in the X-axis direction inthe droplet discharge heads 114 has a prescribed value. The specificvalue of the nozzle pitch HXP is not particularly limited, but may be 50to 90 μm, for example. In this case, “the nozzle pitch HXP in the X-axisdirection in the droplet discharge heads 114” corresponds to the pitchbetween a plurality of nozzle images obtained by projecting all of thenozzles 118 in the droplet discharge heads 114 on the X axis along theY-axis direction.

In the present embodiment, the plurality of nozzles 118 in the dropletdischarge heads 114 forms a nozzle row 116A and a nozzle row 116B, bothof which extend in the X-axis direction. The nozzle row 116A and thenozzle row 116B are disposed in parallel across an interval. In thepresent embodiment, 90 nozzles 118 are aligned in a row in the X-axisdirection with a fixed interval LNP in each nozzle row 116A and nozzlerow 116B. The specific value of LNP is not particularly limited, but maybe 100 to 180 μm, for example.

The position of the nozzle row 116B is offset in the positive directionof the X-axis direction (the right-hand direction of FIG. 5) by half thelength of the nozzle pitch LNP in relation to the position of the nozzlerow 116A. For this reason, the nozzle pitch HXP in the X-axis directionof the droplet discharge heads 114 is half the length of the nozzlepitch LNP of the nozzle row 116A (or the nozzle row 116B).

Therefore, the nozzle line density in the X-axis direction of thedroplet discharge heads 114 is twice the nozzle line density of thenozzle row 11 6A (or the nozzle row 116B). In the present specification,“the nozzle line density in the X-axis direction” corresponds to thenumber per unit length of the plurality of nozzle images obtained byprojecting a plurality of nozzles on the X-axis along the Y-axisdirection. Naturally, the number of nozzle rows included in the dropletdischarge heads 114 is not limited to two rows. The droplet dischargeheads 114 may include M number of nozzle rows. In this case, M is anatural number of 1 or higher. In this case, the plurality of nozzles118 in each of the M number of nozzle rows is aligned at a pitch havinga length that is M times that of the nozzle pitch HXP. In the case thatM is a natural number of 2 or higher, another (M−1) number of nozzlerows are offset in the X-axis direction without overlapping, by a lengthi times that of the nozzle pitch HXP, in relation to a single nozzle rowamong the M number of nozzle rows. Here, i is a natural number from 1 to(M−1).

In the present embodiment, since the nozzle row 116A and the nozzle row116B are each composed of 90 nozzles 118, a single droplet dischargehead 114 has 180 nozzles 118. However, five nozzles at each end of thenozzle row 116A are set as “reserve nozzles.” Similarly, five nozzles ateach end of the nozzle row 116B are set as “reserve nozzles.” The ink 2is not discharged from these 20 “reserve nozzles.” For this reason, 160nozzles 118 among the 180 nozzles 118 in the droplet discharge heads 114function as nozzles for discharging the ink 2.

In the droplet discharge means 103, the plurality of droplet dischargeheads 114 is disposed in two rows along the X-axis direction, as shownin FIG. 4. One of the rows of droplet discharge heads 114 and the otherrow of droplet discharge heads 114 are disposed so that a portion of thedroplet discharge heads overlap as viewed from the Y-axis direction,with consideration given to the reserve nozzles. The nozzles 118 fordischarging the ink 2 are thereby configured so as to be continuous inthe X-axis direction at the nozzle pitch HXP across the length of thedimension in the X-axis direction of the substrate 11 in the dropletdischarge means 103.

In the droplet discharge means 103 of the present embodiment, thedroplet discharge heads 114 are disposed so as to cover the entirelength of the dimension in the X-axis direction of the substrate 11.However, the droplet discharge means in the present invention may covera portion of the length of the dimension in the X-axis direction of thesubstrate 11.

Each of the droplet discharge heads 114 is an inkjet head, as shown inFIGS. 6A and 6B. More specifically, each of the droplet discharge heads114 is provided with a vibration plate 126 and a nozzle plate 128. Afluid reservoir 129 in which the ink 2 fed from the tank 101 via a hole131 is constantly filled is positioned between the vibration plate 126and the nozzle plate 128.

A plurality of partition walls 122 is disposed between the vibrationplate 126 and the nozzle plate 128. The portions enclosed by thevibration plate 126, the nozzle plate 128, and a pair of partition walls122 are cavities 120. Since the cavities 120 are disposed incorrespondence with the nozzles 118, the number of cavities 120 and thenumber of nozzles 118 is the same. The ink 2 is fed to the cavities 120from the fluid reservoir 129 via supply ports 130 positioned betweenpairs of partition walls 122.

An oscillator 124 is positioned on the vibration plate 126 incorrespondence with each of the cavities 120. The oscillator 124includes a piezoelement 124C, and a pair of electrodes 124A, 124B thatsandwich the piezoelement 124C. The ink 2 is discharged from thecorresponding nozzle 118 by applying a drive voltage between the pair ofelectrodes 124A, 124B. The shape of the nozzles 118 is adjusted so thatthe ink 2 is discharged in the Z-axis direction from the nozzles 118.

The control means 112 (see FIG. 3) may be configured so as toindependently apply signals to each of the plurality of oscillators 124.In other words, the volume of the ink 2 discharged from the nozzles 118can be controlled for each nozzle 118 in accordance with a signal fromthe control means 112. The control means 112 can also set the nozzles118 that will perform a discharge operation during a coating scan, aswell as the nozzles 118 that will not perform a discharge operation.

In the present specification, the portion that includes a single nozzle118, a cavity 120 that corresponds to the nozzle 118, and the oscillator124 that corresponds to the cavity 120 will be referred to as a“discharge portion 127”. In accordance with this is designation, asingle droplet discharge head 114 has the same number of dischargeportions 127 as the number of nozzles 118.

The ink 2 corresponding to the plurality of colored portions 12 of thecolor filter 1 is applied to the cells 14 using such a droplet dischargedevice 100. The ink 2 can be selectively applied with good efficiency inthe cells 14 by using such a device. In the configuration shown in thedrawings, the droplet discharge device 100 has a tank 101 for holdingthe ink 2, a tube 110, and other components for only one color, butthese members may have a plurality of colors the correspond to theplurality of colored portions 12 of the color filter 1. Also, in themanufacture of the color filter 1, a plurality of droplet dischargedevices 100 corresponding to a plurality of inks 2 may be used.

In the present embodiment as described above, the ink 2 is applied inthe cells 14 while the substrate 11 is moved in relation to the dropletdischarge head. Applying the ink 2 in this manner makes it possible toincrease the production properties of the color filter 1.

The ink used to manufacture a color filter includes a colorant, a resinmaterial, and other components, and therefore generally has highviscosity. In manufacturing the color filter, the ink is usuallydischarged while the substrate is moved relative to the inkjet head forthe sake of productivity. When an ink having such a relatively highviscosity is discharged, trailing can sometimes occur. Depending on thelanding position of the ink, the trail portion is recovered within thesame cell when the trailing breaks off, but the trail portion sometimesenters an adjacent cell in conjunction with the relative movement of thesubstrate, and the problem of mixing between adjacent cells therebyoccurs. As a result, a color layer having the desired coloration cannotbe formed, and the color reproduction properties of the manufacturedcolor filter are adversely affected. The cell height may be increased soas to prevent such mixing, but when the height of the cells isincreased, a large amount of ink must be discharged, the thickness ofthe color layer increases, and the productivity and light usageefficiency are reduced. The problem of color mixing such as describedabove is severe when the frequency of discharge from the inkjet head isincreased, and the speed of relative movement of the substrate isincreased in order to enhance productivity.

Therefore, as a result of concentrated investigation, the inventorsdiscovered that the problems described above can be overcome byproviding a landing prohibition region in which the landing of ink isprohibited at a predetermined width from the edge of the cells in thedirection in which the substrate moves in relation to the dropletdischarge head. Specifically, the trailing portion of the ink can beprevented from entering an adjacent cell by providing a landingprohibition region that satisfies the relationship 0.5≦L₁/L₂≦0.45,wherein L₁ (μm) is the width of the landing prohibition region, and L₂(μm) is the average diameter of the ink droplets. As a result, colormixing between adjacent colored portions is prevented, and a colorfilter having excellent color reproduction properties can be provided.

In contrast, when L₁/L₂ is less than the lower limit, it is impossibleto prevent the trailing portion of the ink from entering an adjacentcell, and color mixing between adjacent colored portions occurs. WhenL₁/L₂ exceeds the upper limit, it is difficult to cause the ink tospread into the cells, and light leakage (white spots, bright points)results in the color filter.

The present invention is thus characterized in that a landingprohibition region is provided that satisfies the relationship0.5≦L₁/L₂≦4.5, wherein L₁ (μm) is the width of the landing prohibitionregion, and L₂ (μm) is the average diameter of the ink droplets, but therelationship 0.6≦L₁/L₂≦4.3 is more preferably satisfied. Satisfying sucha relationship makes it possible to more significantly demonstrate theeffects of the present invention.

In the present invention, the landing prohibition region is a regionbased on the center of a droplet, and is a region into which the centerof a droplet is not allowed to enter when landing occurs.

In the present invention, the average diameter of the ink droplets isthe average of the diameters in a case in which droplets discharged froma volume of ink discharged in one cycle are spheres having a density of1.0 g/cm³.

In the present invention, the term “direction in which the substratemoves in relation to the droplet discharge head” refers to the primarydirection in which the substrate moves in relation to the dropletdischarge head, and is the Y-axis direction of the drawings in thepresent embodiment.

In the present embodiment, landing prohibition regions 141 in whichlanding of the ink 2 is prohibited are provided at a predetermined widthX from the edges on both sides of the cell 14 in the Y-axis direction(the direction in which the substrate 11 moves in relation to thedroplet discharge head 114), as shown in FIG. 7.

The landing prohibition regions 141 provided to both edges in thismanner are configured so that droplets are prevented from landing withinthe landing prohibition region 141 on the left side in FIG. 7 when thesubstrate 11 is moved to the right in FIG. 7 with respect to the dropletdischarge head 114, and so that droplets are prevented from landingwithin the landing prohibition region 141 on the right side in FIG. 7when the substrate 11 is moved to the left in FIG. 7 with respect to thedroplet discharge head 114. The degree of freedom of the movementdirection of the substrate 11 relative to the droplet discharge head 114can thereby be enhanced, and the production properties of the colorfilter 1 can be effectively enhanced.

The relationship 0.025≦L₁/L₃≦0.5 is preferably satisfied, and therelationship 0.033≦L₁/L₃≦0.4 is more preferably satisfied, wherein L₁(μm) is the width of the landing prohibition region 141, and L₃ (μm) isthe width of the cell 14 in the Y-axis direction. The colors of ink 2can thereby be more effectively prevented from mixing between adjacentcells 14.

The specific width of the landing prohibition region 141 is preferably3.0 to 50.0 μm, and more preferably 5.0 to 45.0 μm. The colors of ink 2can thereby be even more effectively prevented from mixing betweenadjacent cells 14.

The movement speed of the substrate 11 in relation to the dropletdischarge head 114 is preferably 30 to 400 mm/second, and morepreferably 50 to 380 mm/second. The colors of ink 2 can thereby be moreeffectively prevented from mixing between adjacent cells 14.

In the present invention, the droplet discharge heads 114 may use anelectrostatic actuator in place of the piezoelement as the driveelement. The droplet discharge heads 114 may have a configuration inwhich an electrothermal converter is used and colored ink is dischargedusing the thermal expansion of material produced by an electrothermalconverter.

Colored Portion Formation Step (Curing Step)

Next, the solvent (dispersion medium) is removed from the ink 2 in thecells 14, and solid colored portions 12 are formed by curing the resinmaterial included in the ink 2 (1 e). The color filter 1 is obtained inthis manner.

The present step is ordinarily carried out by heating, but in thepresent step, depending on the type of solvent or resin materialconstituting the ink 2, treatments involving irradiation with activeenergy rays, treatments in which the substrate 11 to which the ink 2 hasbeen applied is placed in a reduced-pressure environment, and othertreatments may also be performed, for example. The curing reaction ofthe resin material can be made to proceed with good efficiency byradiating active energy rays; the curing reaction of the resin materialcan be reliably promoted even when the heating temperature is relativelylow; the occurrence of adverse effects on the substrate 11 and othercomponents can reliably prevented; and other effects can be obtained.Examples of the active energy rays that may be used include light raysof various wavelengths, e.g., UV rays, X-rays, g-rays, i-rays, andexcimer laser light. The substrate 11 on which the ink 2 has beenapplied can be placed in a reduced-pressure environment, whereby thesolvent (dispersion medium) can be removed with good efficiency, theshape of the colored portions in the pixels (cells) can be reliably madeinto good preferred shapes, the solvent (dispersion medium) can bereliably removed even when the heating temperature is relatively low,the occurrence of adverse effects on the substrate 11 and the like canbe reliably prevented, and other effects can be obtained.

The heating temperature in the present step is not particularly limited,but 50 to 260° C. is preferred, and 80 to 240° C. is even morepreferred.

Ink (Color Filter Ink)

The ink (color filter ink) used to manufacture the color filter of thepresent invention will next be described in detail.

The color filter ink (also referred to hereinafter as “ink”) includes apigment, a solvent, a dispersing agent, and a curable resin material.

Curable Resin Material

The color ink constituting the color filter ink set includes a curableresin material. The adhesion of the colored portion formed using thecolor filter ink to the substrate can thereby be enhanced. Adverseeffects on the colored portion can also be prevented when chemicalapplication or washing is performed in a step subsequent to the inkapplication step by the inkjet method.

Such curable resin materials are not particularly limited, but thecurable resin material preferably includes an epoxy-based resin. Theadhesion of the formed colored portion to the substrate can thereby beeven further enhanced. The colored portion can also be provided withhigher chemical resistance (solvent resistance).

The epoxy-based resin preferably includes a polymer A (first polymer)that contains at least an epoxy-containing vinyl monomer a1 (firstepoxy-containing vinyl monomer) as a monomer component. The formedcolored portion can thereby be provided with particularly excellentadhesion to the substrate, chemical resistance (solvent resistance), andother characteristics, and the ink can be provided with particularlyexcellent discharge stability. As a result, it is possible to morereliably prevent problems such as variation of the trajectory of thedischarged droplets (so-called flight deflection), inability to land thedroplets in the desired position, instability of the droplet dischargequantity, and other problems even when droplets of the ink aredischarged over long periods, or droplet discharge is performedcontinuously.

Polymer A

The polymer A will be described in detail below.

The polymer A contains at least the epoxy-containing vinyl monomer a1 asa monomer component. The polymer A may be composed of essentially asingle compound, or may be a mixture of a plurality of types ofcompounds. However, when the polymer A is a mixture of a plurality oftypes of compounds, each of the compounds contains at least theepoxy-containing vinyl monomer a1 as a monomer component.

Epoxy-Containing Vinyl Monomer a1

The polymer A contains at least the epoxy-containing vinyl monomer a1 asa monomer component. Including such an epoxy-containing vinyl monomer a1as a monomer component makes it possible to easily and reliablyintroduce an epoxy group into the polymer A. By including theepoxy-containing vinyl monomer a1 as a monomer component, the dischargestability of the ink can be enhanced, and color mixing of the coloredportions (inks) between adjacent cells can be more effectivelyprevented. By including the epoxy-containing vinyl monomer a1 as amonomer component, excellent dispersion stability of the pigment such asdescribed above in the ink can be obtained, and the ink can be providedwith excellent storage stability (long-term storage properties).Including the epoxy-containing vinyl monomer a1 as a monomer componentalso enables the colored portion formed using the ink to have excellentchemical resistance (solvent resistance). Including the epoxy-containingvinyl monomer a1 as a monomer component also causes the curing reactionto proceed relatively gradually when the colored portion is formed, andmakes it possible to effectively prevent uneven color and other effectsdue to rapid curing. Including the epoxy-containing vinyl monomer a1 isalso advantageous because the formed colored portion can be providedwith excellent hardness and other characteristics. When the polymer Aincludes a vinyl monomer a2 (second vinyl monomer), a vinyl monomer a3(third vinyl monomer), and other components such as describedhereinafter, the polymer can be suitably synthesized, and a polymer Ahaving the desired characteristics can be easily and reliably obtained.

The epoxy-containing vinyl monomer a1 used may have the structureindicated by Formula (3) below, for example. When the epoxy-containingvinyl monomer a1 has such a structure, the dispersion stability of thepigment such as described above in the ink can be made particularlyexcellent, and the ink can be provided with particularly excellentstorage stability and discharge stability. As a result, color mixing ofthe colored portions (inks) between adjacent cells can be moreeffectively prevented. When the epoxy-containing vinyl monomer a1 hasthe structure indicated by Formula (3) below, the formed colored portioncan be provided with more superior solvent resistance. When theepoxy-containing vinyl monomer a1 has the structure indicated by Formula(3) below, the curing reaction proceeds relatively gradually when thecolored portion is formed, and uneven color and other effects due torapid curing can be effectively prevented. This is advantageous becausethe formed colored portion is also provided with excellent hardness andother characteristics. When the epoxy-containing vinyl monomer a1 hassuch a structure, the polymer A can be provided with particularlyexcellent compatibility with the polymer B (second polymer) describedhereinafter, and the formed colored portion can be provided withparticularly high transparency.

In Formula (3), R⁶ is a hydrogen atom or a C₁₋₇ alkyl group; G is asingle bond hydrocarbon group or a bivalent hydrocarbon group which maycontain a hetero atom; J is an epoxy group or an alicyclic epoxy groupwhich may have a ring-structured C₃₋₁₀ substituted group; and m is 0 or1.

In Formula (3), examples of the C₁₋₇ alkyl group indicated by R⁶ includemethyl, ethyl, propyl, isopropyl, butyl, isobutyl, s-butyl, pentyl,hexyl, heptyl, and other alkyl groups, but a hydrogen atom or a C₁₋₂alkyl group is preferred, and a hydrogen atom or a methyl group is morepreferred. The dispersion stability of the colorant in the ink canthereby be made particularly excellent, and the ink can be provided withparticularly excellent long-term storage properties and dischargestability. As a result, color mixing of the colored portions (inks)between adjacent cells can be more effectively prevented. The contrastof the displayed image can also be made particularly excellent in themanufactured color filter. The formed colored portion can also beprovided with excellent hardness and other characteristics. The polymerA can also be provided with particularly excellent compatibility withthe polymer B described hereinafter, and the formed colored portion canbe provided with extremely high transparency.

Typical examples of bivalent hydrocarbon groups which may contain ahetero atom indicated by G in Formula (3) include straight-chain orbranched alkylene groups, or more specifically, methylenes, ethylenes,propylenes, tetramethylenes, ethyl ethylenes, pentamethylenes,hexamethylenes, oxymethylenes, oxyethylenes, oxypropylenes, and thelike.

Specific examples of the epoxy-containing vinyl monomer a1 includeglycidyl(meth)acrylate, methylglycidyl(meth)acrylate,ethylglycidyl(meth)acrylate, glycidyl vinylbenzyl ether (product name:VBGE; manufactured by Seimi Chemical), the alicyclic epoxy-containingunsaturated compounds indicated by Formulas (3-1) through (3-31) below,and the like; and one or more types of these compounds may be selectedand used, but(3,4-epoxycyclohexyl)methyl(meth)acrylate is particularlypreferred as the epoxy-containing vinyl monomer a1. The dispersionstability of the colorant in the ink can thereby be made particularlyexcellent, and the color filter ink can be provided with particularlyexcellent long-term storage properties and discharge stability. As aresult, color mixing of the colored portions (inks) between adjacentcells can be more effectively prevented. The formed colored portion canalso be provided with particularly excellent hardness, solventresistance, and other characteristics. The polymer A can be providedwith particularly excellent compatibility with the polymer B describedhereinafter, and the colored portion formed using the ink can beprovided with extremely high transparency.

In Formulas (3-1) through (3-31), R⁷ is a hydrogen atom or a methylgroup; R⁸ is a C₁₋₈ bivalent hydrocarbon group; and R⁹ is a C₁₋₂₀bivalent hydrocarbon group. R⁷, R⁸, and R⁹ may be mutually the same ordifferent, and w is 0 to 10.

The content ratio (which is a value obtained by substitution with theweight of the monomer used to synthesize the polymer) of theepoxy-containing vinyl monomer a1 in the polymer A is preferably 50 to99 wt %, and more preferably 70 to 94 wt %. When the content ratio ofthe epoxy-containing vinyl monomer a1 in the polymer A is within theaforementioned range, the dispersion stability of the colorant in theink can be made excellent, and the ink can be provided with excellentlong-term storage properties and excellent discharge stability. As aresult, color mixing of the colored portions (inks) between adjacentcells can be more effectively prevented. When the content ratio of theepoxy-containing vinyl monomer a1 in the polymer A is within theaforementioned range, the curing reaction proceeds relatively graduallywhen the colored portion is formed, uneven color and other effects dueto rapid curing can be effectively prevented, and the formed coloredportion can be provided with particularly excellent hardness, solventresistance, and other characteristics. When the polymer A is a mixtureof a plurality of types of compounds, the weighted average value(weighted average value based on weight ratio) of the mixed compoundsmay be used as the content ratio of the epoxy-containing vinyl monomera1. When the polymer A is a mixture of a plurality of types ofcompounds, the compounds all preferably contain the epoxy-containingvinyl monomer a1 in such a content ratio as described above.

Vinyl Monomer a2

The polymer A may contain at least the epoxy-containing vinyl monomer a1as a monomer component, but the polymer A is preferably one (acopolymer) containing the epoxy-containing vinyl monomer a1, as well asa vinyl monomer a2 as a monomer group provided with an isocyanate groupor a blocked isocyanate group in which the isocyanate group is protectedby a protective group. The content ratio of gas (dissolved gas, bubblespresent as microbubbles, or the like) in the ink can thereby be reducedmore effectively, and particularly excellent stability of dropletdischarge by the inkjet method can be obtained. As a result, colormixing of the colored portions (inks) between adjacent cells can be moreeffectively prevented, and it is possible to more effectively preventthe occurrence of uneven color, uneven saturation, and the like betweendifferent regions of the manufactured color filter, and fluctuation ofcharacteristics between individual units.

Examples of polymerizable vinyl monomers a2 include 2-acryloyloxyethylisocyanate (product name: Karenz MOI; manufactured by Showa Denko),2-methacryloyloxyethyl isocyanate, and other (meth)acryloyl isocyanatesand the like in which (meth)acryloyl is bonded with an isocyanate groupvia a C₂₋₆ alkylene group.

The isocyanate group of the abovementioned (meth)acryloyl isocyanate ispreferably a blocked isocyanate group. The term “blocked isocyanategroup” refers to an isocyanate group in which the terminal ends aremasked by a blocking agent. Examples of monomers having a blockedisocyanate group include2-(0-[1′-methylpropylideneamino]carboxyamino)ethyl methacrylate and thelike, and are commercially available under the trade name Karenz MOI-BM,manufactured by Showa Denko. A combination of one or more types of thesepolymerizable vinyl monomers may be used.

The content ratio (which is a value obtained by substitution with theweight of the monomer used to synthesize the polymer) of the vinylmonomer a2 in the polymer A is preferably 2 to 20 parts by weight, andmore preferably 3 to 15 parts by weight, with respect to 100 parts byweight of the epoxy-containing vinyl monomer a1. When the content ratioof the vinyl monomer a2 in the polymer A is within the aforementionedrange, the content ratio of gas (dissolved gas, bubbles present asmicrobubbles, or the like) in the ink can be reduced more effectively,and particularly excellent stability of droplet discharge by the inkjetmethod can be obtained while the ink is provided with adequatelyexcellent storage stability and other characteristics. As a result,color mixing of the colored portions (inks) between adjacent cells canbe more effectively prevented. The formed colored portion can also beprovided with adequately high transparency. In contrast, when thecontent ratio of the vinyl monomer a2 in the polymer A is less than thelower limit of the aforementioned range, the effects of including avinyl monomer a2 such as those described above may not be adequatelydemonstrated. When the content ratio of the vinyl monomer a2 in thepolymer A exceeds the upper limit of the aforementioned range, thecompatibility of the polymer A with the polymer B described hereinafterdecreases, and the formed colored portion may be difficult to providewith adequate transparency. When the polymer A is a mixture of aplurality of types of compounds, the weighted average value (weightedaverage value based on weight ratio) of the mixed compounds may be usedas the content ratio of the vinyl monomer a2. When the polymer A is amixture of a plurality of types of compounds, the compounds allpreferably contain the vinyl monomer a2 in such a content ratio asdescribed above.

Vinyl Monomer a3

The polymer A may contain at least the epoxy-containing vinyl monomer a1as a monomer component, but the polymer A is preferably one (acopolymer) containing the epoxy-containing vinyl monomer a1, as well asa vinyl monomer a3 provided with a hydroxyl group. The formed coloredportion can thereby be provided with particularly excellent adhesion tothe substrate, particularly adhesion under repeated exposure to suddentemperature changes that accompany image display. As a result, theoccurrence of light leakage (white spots, bright points) and otherproblems can be reliably prevented even when the color filter is usedfor a long time, for example. Specifically, the color filter can beprovided with particularly excellent durability. When the polymer Acontains the vinyl monomer a3 as a monomer component, the polymer A canbe provided with particularly excellent compatibility with the polymer Bdescribed hereinafter, and the formed colored portion can be providedwith extremely high transparency.

Examples of the vinyl monomer a3 include monoester compounds of aacrylic acid or methacrylic acid with 2-hydroxyethyl(meth)acrylate,hydroxypropyl(meth)acrylate, 2,3-dihydroxybutyl(meth)acrylate,4-hydroxybutyl(meth)acrylate, 6-hydroxyhexyl(meth)acrylate,8-hydroxyoctyl(meth)acrylate, 4-hydroxymethyl cyclohexyl(meth)acrylate,polyalkylene glycol mono(meth)acrylate, and other polyalcohols;compounds in which ε-caprolactone is ring-open polymerized with theabovementioned monoester compounds of a polyalcohol and acrylic acid ormethacrylic acid (PLACCEL FA series, PLACCEL FM series, and the likemanufactured by Daicel Chemical Industries); compounds in which ethyleneoxide and propylene oxide is ring-open polymerized; and the like, andone or more types of compounds selected from the above examples may beused.

The content ratio (which is a value obtained by substitution with theweight of the monomer used to synthesize the polymer) of the vinylmonomer a3 in the polymer A is preferably 2 to 20 parts by weight, andmore preferably 3 to 15 parts by weight, with respect to 100 parts byweight of the epoxy-containing vinyl monomer a1. When the content ratioof the vinyl monomer a3 in the polymer A is within the aforementionedrange, the color filter manufactured using the ink can be provided withparticularly excellent durability while the ink is provided withadequately excellent storage stability and other characteristics. Theformed colored portion can also be provided with high transparency. Incontrast, when the content ratio of the vinyl monomer a3 in the polymerA is less than the lower limit of the aforementioned range, the effectsof including a vinyl monomer a3 such as those described above may not beadequately demonstrated. When the content ratio of the vinyl monomer a3in the polymer A exceeds the upper limit of the aforementioned range, itmay be difficult to make the content ratio of gas in the ink adequatelylow. When the polymer A is a mixture of a plurality of types ofcompounds, the weighted average value (weighted average value based onweight ratio) of the mixed compounds may be used as the content ratio ofthe vinyl monomer a3. When the polymer A is a mixture of a plurality oftypes of compounds, the compounds all preferably contain the vinylmonomer a3 in such a content ratio as described above.

Other Polymerizable Vinyl Monomer a4

The polymer A may contain as a monomer component a polymerizable vinylmonomer a4 other than the epoxy-containing vinyl monomer a1, the vinylmonomer a2, and the vinyl monomer a3 described above. A vinyl monomerthat can be copolymerized with the epoxy-containing vinyl monomer a1 maybe used as the polymerizable vinyl monomer a4, and specific examplesthereof include methyl(meth)acrylate, ethyl(meth)acrylate,butyl(meth)acrylate, 2-ethylhexyl(meth)acrylate, phenyl(meth)acrylate,cyclohexyl(meth)acrylate, dicyclopentanyl(meth)acrylate,dicyclopentanyloxyethyl(meth)acrylate, isobornyl(meth)acrylate,benzyl(meth)acrylate, phenyl ethyl(meth)acrylate, and other C₁₋₁₂ alkyland aralkyl (meth)acrylates; styrene, α-methylstyrene, and other vinylaromatic compounds; CF₃(CF₂)₃CH₂CH═CH₂, CF₃(CF₂)₃CH═CH₂,CF₃(CF₂)₅CH₂CH═CH₂, CF₃(CF₂)₅CH═CH₂, CF₃(CF₂)₇CH═CH₂,CF₃(CF₂)₉CH₂CH═CH₂, CF₃(CF₂)₉CH═CH₂, (CF₃)₂CF(CF₂)₂CH₂CH═CH₂,(CF₃)₂CF(CF₂)₂CH═CH₂, (CF₃)₂CF(CF₂)₄CH₂CH═CH₂, (CF₃)₂CF(CF₂)₄CH═CH₂,(CF₃)₂CF(CH₂)₆CH₂CH═CH₂, (CF₃)₂CF(CF₂)₆CH═CH₂, F₅C₆CH═CH₂,CF₃(CF₂)₅CH₂CH₂OCH₂CH═CH₂, CF₃(CF₂)₅CH₂CH₂CH₂OCH₂CH═CH₂,CF₃(CF₂)₇CH₂CH₂OCH₂CH═CH₂, CF₃(CF₂)₇CH₂CH₂CH₂OCH₂CH═CH₂,CF₃(CF₂)₉CH₂CH₂OCH₂CH═CH₂, CF₃(CF₂)₉CH₂CH₂CH₂OCH₂CH═CH₂,H(CF₂)₆CH₂OCH₂CH═CH₂, H(CF₂)₈CH₂OCH₂CH═CH₂,(CF₃)₂CF(CF₂)₂CH₂CH₂OCOCH═CH₂, (CF₃)₂CF(CF₂)₂CH₂CH₂OCOC(CH₃)═CH₂,(CF₃)₂CF(CF₂)₄CH₂CH₂OCOCH═CH₂, (CF₃)₂CF(CF₂)₄CH₂CH₂OCOC(CH₃)═CH₂,(CF₃)₂CF(CF₂)₆CH₂CH₂OCOCH═CH₂, (CF₃)₂CF(CF₂)₆CH₂CH₂OCOC(CH₃)═CH₂,CF₃(CF₂)₅CH₂CH₂OCOCH═CH₂, CF₃(CF₂)₅CH₂CH₂OCOC(CH₃)═CH₂,CF₃(CF₂)₇CH₂CH₂OCOCH═CH₂, CF₃(CF₂)₇CH₂CH₂OCOC(CH₃)═CH₂,CF₃(CF₂)₉CH₂CH₂OCOCH═CH₂, CF₃(CF₂)₉CH₂CH₂OCOC(CH₃)═CH₂,H(CF₂)₆CH₂CH₂OCOCH═CH₂, H(CF₂)₈CH₂CH₂OCOC(CH₃)═CH₂,F(CF₂)₈CH₂CH₂OCOCH═CH₂, F(CF₂)₈CH₂CH₂OCOC(CH₃)═CH₂,H(CF₂)₄CH₂OCOC(CH₃)═CH₂, H(CF₂)₄CH₂OCOCH═CH₂, and other fluoroalkyl- orfluoroaryl-containing vinyl compounds and the like, and one or moretypes of compounds selected from the above examples may be combined andused. However, the polymer A does not contain as a monomer component analkoxysilyl-containing vinyl monomer b1 such as described hereinafter.

The content ratio (which is a value obtained by substitution with theweight of the monomer used to synthesize the polymer) of thepolymerizable vinyl monomer a4 in the polymer A is preferably 20 partsby weight or less, and more preferably 10 parts by weight or less withrespect to 100 parts by weight of the epoxy-containing vinyl monomer a1.When the polymer A is a mixture of a plurality of types of compounds,the weighted average value (weighted average value based on weightratio) of the mixed compounds may be used as the content ratio of thepolymerizable vinyl monomer a4. When the polymer A is a mixture of aplurality of types of compounds, the content ratio of the polymerizablevinyl monomer a4 with respect to the mixture of compounds preferablysatisfies such conditions as those described above.

As described above, the polymer A may contain at least theepoxy-containing vinyl monomer a1 as a monomer component, but preferablycontains the epoxy-containing vinyl monomer a1 as well as the vinylmonomer a2 and the vinyl monomer a3. The effects of including a vinylmonomer a2 such as the ones described above, and the effects ofincluding a vinyl monomer a3 such as the ones described above can beobtained at the same time.

The ratio (content ratio) accounted for by the polymer A in the curableresin material (binder resin) is not particularly limited, but ispreferably 25 to 80 wt %, and more preferably 33 to 70 wt %. When thepolymer A is a mixture of a plurality of types of compounds, the sum ofthe content ratios of the mixed compounds may be used as the contentratio of the polymer A.

Polymer B

Besides the abovementioned components, the curable resin material mayinclude a polymer B that contains at least the alkoxysilyl-containingvinyl monomer b1 indicated by Formula (1) below as a monomer component.

In Formula (1), R¹ is a hydrogen atom or a C₁₋₇ alkyl group; E is asingle bond hydrocarbon group or a bivalent hydrocarbon group; R² and R³are the same or different C₁₋₆ alkyl groups or C₁₋₆ alkoxyl groups; R⁴is a C₁₋₆ alkyl group; x is 0 or 1; and y is an integer from 1 to 10.

Such a polymer B is preferably used together with the previouslydescribed polymer A. The content ratio of gas in the ink can thereby bereduced, and the ink can be provided with particularly excellentdischarge stability. As a result, color mixing of the colored portions(inks) between adjacent cells can be more effectively prevented.Including the polymer B together with the polymer A in the curable resinmaterial also makes it possible to provide the manufactured color filterwith particularly excellent durability. Excellent mixing stability ofthe curable resin material and the colorant can also be obtained over along period of time, and color filters having excellent contrast can bestably manufactured over a long period of time. Including the polymer Btogether with the polymer A in the curable resin material also makes itpossible to provide the formed colored portion with excellent lightfastness. Dyes generally have inferior light fastness in comparison topigments, but the formed colored portion can be provided with adequatelyexcellent light fastness even when the ink includes a dye as thecolorant. Since the ink, once prepared, can be suitably used for a longtime, the frequency of replacing the ink and replacing the ink in thedroplet discharge device can be reduced. The color filter can thereforebe manufactured with particularly excellent productivity, and theconsistency of quality of the manufactured color filter is enhanced.

The polymer B may be composed of essentially a single compound, or maybe a mixture of a plurality of types of compounds. However, when thepolymer B is a mixture of a plurality of types of compounds, each of thecompounds contains at least the alkoxysilyl-containing vinyl monomer b1as a monomer component.

Alkoxysilyl-Containing Vinyl Monomer b1

The polymer B contains at least the alkoxysilyl-containing vinyl monomerb1 indicated by Formula (1) as a monomer component. Including such analkoxysilyl-containing vinyl monomer b1 as a monomer component makes itpossible to easily and reliably introduce an alkoxysilyl group into thepolymer B. By including the alkoxysilyl-containing vinyl monomer b1 as amonomer component, the formed colored portion can be provided withadequately excellent hardness, adhesion to the substrate, lightfastness, thermal resistance, and other characteristics. When thepolymer B includes a vinyl monomer b2 or the like such as describedhereinafter, the polymer can be suitably synthesized, and a polymer Bhaving the desired characteristics can be easily and reliably obtained.

In Formula (1), examples of the C₁₋₇ alkyl group indicated by R¹ includemethyl, ethyl, propyl, isopropyl, butyl, isobutyl, s-butyl, pentyl,hexyl, heptyl, and other alkyl groups, but a hydrogen atom or a C₁₋₂alkyl group is preferred, and a hydrogen atom or a methyl group is morepreferred. The color filter ink can thereby be provided withparticularly excellent dispersion stability of the pigment in the colorfilter ink (ink), and discharge stability of the color filter ink, andthe formed colored portion can be provided with particularly excellenthardness, adhesion to the substrate, light fastness, thermal resistance,and other characteristics. The polymer A can also be provided withparticularly excellent compatibility with the polymer B, and the formedcolored portion can be provided with particularly high transparency.

Typical examples of the bivalent hydrocarbon group indicated by E inFormula (1) include straight-chain or branched alkylene groups, or morespecifically, methylenes, ethylenes, propylenes, tetramethylenes, ethylethylenes, pentamethylenes, hexamethylenes, and the like. Among theseexamples, a C₁₋₃ straight-chain alkylene group (e.g., methylene,ethylene, propylene) is particularly preferred.

Examples of the C₁₋₆ alkyl groups indicated by R², R³, and R⁴ in Formula(1) include straight-chain or branched alkyl groups, e.g., methyl,ethyl, propyl, isopropyl, butyl, isobutyl, s-butyl, pentyl, hexyl, andthe like. Examples of the C₁₋₆ alkoxyl groups indicated by R² and R³include straight-chain or branched alkoxyl groups, e.g., methoxy,ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, s-butoxy, pentoxy,hexyloxy, and the like.

Specific examples of monomers indicated by Formula (1) includevinyltrimethoxysilane, vinyltriethoxysilane, vinylmethyldimethoxysilane,vinylmethyldiethoxysilane, γ-(meth)acryloyloxypropyltrimethoxysilane,γ-(meth)acryloyloxypropylmethyldimethoxysilane,γ-(meth)acryloyloxypropylmethyldiethoxysilane,γ-(meth)acryloyloxypropyltriethoxysilane,β-(meth)acryloyloxyethyltrimethoxysilane,γ-(meth)acryloyloxybutylphenyldimethoxysilane, and otheralkoxysilyl-containing polymerizable unsaturated compounds and the like,and one or more types of compounds selected from the above examples maybe combined and used.

The content ratio (which is a value obtained by substitution with theweight of the monomer used to synthesize the polymer) of thealkoxysilyl-containing vinyl monomer b1 in the polymer B is preferably70 to 100 wt %, and more preferably 80 to 100 wt %. When the contentratio of the alkoxysilyl-containing vinyl monomer b1 in the polymer B iswithin the aforementioned range, the ink can be provided withparticularly excellent dispersion stability of the pigment in the ink,and discharge stability of the ink. The formed colored portion can alsobe provided with particularly excellent hardness, adhesion to thesubstrate, light fastness, thermal resistance, and othercharacteristics. When the polymer B is a mixture of a plurality of typesof compounds, the weighted average value (weighted average value basedon weight ratio) of the mixed compounds may be used as the content ratioof the alkoxysilyl-containing vinyl monomer b1. When the polymer B is amixture of a plurality of types of compounds, the compounds allpreferably contain the alkoxysilyl-containing vinyl monomer b1 in such acontent ratio as described above.

Other Polymerizable Vinyl Monomer b2

The polymer B may contain at least the alkoxysilyl-containing vinylmonomer b1 as a monomer component, but may also contain as a monomercomponent a polymerizable vinyl monomer b2 other than thealkoxysilyl-containing vinyl monomer b1, in addition to thealkoxysilyl-containing vinyl monomer b1. A vinyl monomer that can becopolymerized with the alkoxysilyl-containing vinyl monomer b1 may beused as the polymerizable vinyl monomer b2, and specific examplesthereof include 2-hydroxyethyl(meth)acrylate,hydroxypropyl(meth)acrylate, 2,3-dihydroxybutyl(meth)acrylate,4-hydroxybutyl(meth)acrylate, 6-hydroxyhexyl(meth)acrylate,8-hydroxyoctyl(meth)acrylate, 4-hydroxymethyl cyclohexyl(meth)acrylate,polyalkylene glycol mono(meth)acrylate, and other monoester compounds ofa polyalcohol and acrylic acid or methacrylic acid; compounds in whichε-caprolactone is ring-open polymerized with the abovementionedmonoester compounds of a polyalcohol and acrylic acid or methacrylicacid (PLACCEL FA series, PLACCEL FM series, and the like manufactured byDaicel Chemical Industries); compounds in which ethylene oxide andpropylene oxide is ring-open polymerized, and other polymerizable vinylmonomers provided with a hydroxyl group; methyl(meth)acrylate,ethyl(meth)acrylate, butyl(meth)acrylate, 2-ethylhexyl(meth)acrylate,phenyl(meth)acrylate, cyclohexyl(meth)acrylate,dicyclopentanyl(meth)acrylate, dicyclopentanyloxyethyl(meth)acrylate,isobornyl(meth)acrylate, benzyl(meth)acrylate, phenylethyl(meth)acrylate, and other C₁₋₁₂ alkyl and aralkyl(meth)acrylates;styrene, α-methylstyrene, and other vinyl aromatic compounds;CF₃(CF₂)₃CH₂CH═CH₂, CF₃(CF₂)₃CH═CH₂, CF₃(CF₂)₅CH₂CH═CH₂,CF₃(CF₂)₅CH═CH₂, CF₃(CF₂)₇CH═CH₂, CF₃(CF₂)₉CH₂CH═CH₂, CF₃(CF₂)₉CH═CH₂,(CF₃)₂CF(CF₂)₂CH₂CH═CH₂, (CF₃)₂CF(CF₂)₂CH═CH₂, (CF₃)₂CF(CF₂)₄CH₂CH═CH₂,(CF₃)₂CF(CF₂)₄CH═CH₂, (CF₃)₂CF(CF₂)₆CH₂CH═CH₂, (CF₃)₂CF(CF₂)₆CH═CH₂,F₅C₆CH═CH₂, CF₃(CF₂)₅CH₂CH₂OCH₂CH═CH₂, CF₃(CF₂)₅CH₂CH₂CH₂OCH₂CH═CH₂,CF₃(CF₂)₇CH₂CH₂OCH₂CH═CH₂, CF₃(CF₂)₇CH₂CH₂CH₂OCH₂CH═CH₂,CF₃(CF₂)₉CH₂CH₂OCH₂CH═CH₂, CF₃(CF₂)₉CH₂CH₂CH₂OCH₂CH═CH₂,H(CF₂)₆CH₂OCH₂CH═CH₂, H(CF₂)₈CH₂OCH₂CH═CH₂,(CF₃)₂CF(CF₂)₂CH₂CH₂OCOCH═CH₂, (CF₃)₂CF(CF₂)₂CH₂CH₂OCOC(CH₃)═CH₂,(CF₃)₂CF(CF₂)₄CH₂CH₂OCOCH═CH₂, (CF₃)₂CF(CF₂)₄CH₂CH₂OCOC(CH₃)═CH₂,(CF₃)₂CF(CF₂)₆CH₂CH₂OCOCH═CH₂, (CF₃)₂CF(CF₂)₆CH₂CH₂OCOC(CH₃)═CH₂,CF₃(CF₂)₅CH₂CH₂OCOCH═CH₂, CF₃(CF₂)₅CH₂CH₂OCOC(CH₃)═CH₂,CF₃(CF₂)₇CH₂CH₂OCOCH═CH₂, CF₃(CF₂)₇CH₂CH₂OCOC(CH₃)═CH₂,CF₃(CF₂)₉CH₂CH₂OCOCH═CH₂, CF₃(CF₂)₉CH₂CH₂OCOC(CH₃)═CH₂,H(CF₂)₆CH₂CH₂OCOCH═CH₂, H(CF₂)₈CH₂CH₂OCOC(CH₃)═CH₂,F(CF₂)₈CH₂CH₂OCOCH═CH₂, F(CF₂)₈CH₂CH₂OCOC(CH₃)═CH₂,H(CF₂)₄CH₂OCOC(CH₃)═CH₂, H(CF₂)₄CH₂OCOCH═CH₂, and other fluoroalkyl- orfluoroaryl-containing vinyl monomers and the like, and one or more typesof compounds selected from the above examples may be combined and used.However, the polymer B does not contain as a monomer component anepoxy-containing vinyl monomer a1 such as previously described. Thepolymer B also preferably does not contain a fluoroalkyl- orfluoroaryl-containing vinyl monomer such as described above as a monomercomponent.

The content ratio (which is a value obtained by substitution with theweight of the monomer used to synthesize the polymer) of thepolymerizable vinyl monomer b2 in the polymer B is preferably 30 wt % orless, and more preferably 20 wt % or less. When the polymer B is amixture of a plurality of types of compounds, the weighted average value(weighted average value based on weight ratio) of the mixed compoundsmay be used as the content ratio of the polymerizable vinyl monomer b2.When the polymer B is a mixture of a plurality of types of compounds,the content ratio of the polymerizable vinyl monomer b2 with respect tothe mixture of compounds preferably satisfies such conditions as thosedescribed above.

As described above, the polymer B may contain at least thealkoxysilyl-containing vinyl monomer b1 as a monomer component, and maycontain a monomer component other than the alkoxysilyl-containing vinylmonomer b1, but is preferably a homopolymer of thealkoxysilyl-containing vinyl monomer b1. Specifically, the polymer Bpreferably does not contain components other than thealkoxysilyl-containing vinyl monomer b1 as monomer components. Thedispersion stability of the pigment in the ink, the discharge stabilityof the ink, and the durability of the manufactured color filter canthereby be made particularly excellent.

The ratio (content ratio) accounted for by the polymer B in the curableresin material is not particularly limited, but is preferably 20 to 60wt %, and more preferably 25 to 55 wt %. When the polymer B is a mixtureof a plurality of types of compounds, the sum of the content ratios ofthe mixed compounds may be used as the content ratio of the polymer B.

The ratio of the polymer A content and the polymer B content in terms ofweight is preferably 25:75 to 75:25, and more preferably 45:55 to 55:45.Satisfying such conditions enables the ink to be provided withparticularly excellent dispersion stability of the colorant in the ink,and discharge stability of the ink. The manufactured color filter can beprovided with excellent uniformity of characteristics between individualunits, and unevenness of color and saturation between different regionscan be more reliably prevented. The color filter can also be providedwith excellent durability.

Polymer C

Besides the abovementioned components, the curable resin material mayfurthermore include a polymer C (third polymer) that contains as amonomer component the fluoroalkyl- or fluoroaryl-containing vinylmonomer c1 indicated by Formula (2) below.

In Formula (2), R⁵ is a hydrogen atom or a C₁₋₇ alkyl group; D is asingle bond hydrocarbon group or a bivalent hydrocarbon group which maycontain a hetero atom; Rf is a C₁₋₂₀ fluoroalkyl group or fluoroarylgroup; and z is 0 or 1.

Such a polymer C is preferably used together with the polymer A and thepolymer B. the ink can thereby be provided with particularly excellentdischarge stability. In particular, fluid depletion from the nozzles ofthe droplet discharge head can be improved, and such problems as solidcomponents of the color filter ink adhering to the nozzles can be moreeffectively prevented. As a result, color mixing of the colored portions(inks) between adjacent cells can be more effectively prevented. Thecolored portion formed using the color filter ink can also be providedwith particularly excellent thermal resistance.

The polymer C may be composed of essentially a single compound, or maybe a mixture of a plurality of types of compounds. However, when thepolymer C is a mixture of a plurality of types of compounds, each of thecompounds contains at least the fluoroalkyl- or fluoroaryl-containingvinyl monomer c1 as a monomer component.

Fluoroalkyl- or Fluoroaryl-Containing Vinyl Monomer c1

The polymer C contains at least the fluoroalkyl- orfluoroaryl-containing vinyl monomer c1 indicated by Formula (2) as amonomer component. Including such a fluoroalkyl- orfluoroaryl-containing vinyl monomer c1 as a monomer component makes itpossible to easily and reliably introduce a fluoroalkyl group or afluoroaryl group into the polymer C. Including the fluoroalkyl- orfluoroaryl-containing vinyl monomer c1 as a monomer component enablesthe ink to be provided with particularly excellent discharge stability.The formed colored portion can also be provided with particularlyexcellent thermal resistance. When the polymer C includes a vinylmonomer c2 or the like such as described hereinafter, the polymer can besuitably synthesized, and a polymer C having the desired characteristicscan be easily and reliably obtained.

Examples of the C₁₋₇ alkyl group indicated by R⁵ in Formula (2) includemethyl, ethyl, propyl, isopropyl, butyl, isobutyl, s-butyl, pentyl,hexyl, heptyl, and other alkyl groups, but a hydrogen atom or a C₁₋₂alkyl group is preferred, and a hydrogen atom or a methyl group is morepreferred. The discharge stability of the ink and the thermal resistanceof the formed colored portion can thereby be made particularlyexcellent.

Typical examples of the bivalent hydrocarbon group (hydrocarbon groupwhich may contain a hetero atom) indicated by D in Formula (2) includestraight-chain or branched alkylene groups, or more specifically,methylenes, ethylenes, propylenes, tetramethylenes, ethyl ethylenes,pentamethylenes, hexamethylenes, oxymethylenes, oxyethylenes,oxypropylenes, and the like.

Specific examples of monomers indicated by Formula (2) includeCF₃(CF₂)₃CH₂CH═CH₂, CF₃(CF₂)₃CH═CH₂, CF₃(CF₂)₅CH₂CH═CH₂,CF₃(CF₂)₅CH═CH₂, CF₃(CF₂)₇CH═CH₂, CF₃(CF₂)₉CH₂CH═CH₂, CF₃(CF₂)₉CH═CH₂,(CF₃)₂CF(CF₂)₂CH₂CH═CH₂, (CF₃)₂CF(CF₂)₂CH═CH₂, (CF₃)₂CF(CF₂)₄CH₂CH═CH₂,(CF₃)₂CF(CF₂)₄CH═CH₂, (CF₃)₂CF(CF₂)₆CH₂CH═CH₂, (CF₃)₂CF(CF₂)₆CH═CH₂,F₅C₆CH═CH₂, CF₃(CF₂)₅CH₂CH₂OCH₂CH═CH₂, CF₃(CF₂)₅CH₂CH₂CH₂OCH₂CH═CH₂,CF₃(CF₂)₇CH₂CH₂OCH₂CH═CH₂, CF₃(CF₂)₇CH₂CH₂CH₂OCH₂CH═CH₂,CF₃(CF₂)₉CH₂CH₂OCH₂CH═CH₂, CF₃(CF₂)₉CH₂CH₂CH₂OCH₂CH═CH₂,H(CF₂)₆CH₂OCH₂CH═CH₂, H(CF₂)₈CH₂OCH₂CH═CH₂,(CF₃)₂CF(CF₂)₂CH₂CH₂OCOCH═CH₂, (CF₃)₂CF(CF₂)₂CH₂CH₂OCOC(CH₃)═CH₂,(CF₃)₂CF(CF₂)₄CH₂CH₂OCOCH═CH₂, (CF₃)₂CF(CF₂)₄CH₂CH₂OCOC(CH₃)═CH₂,(CF₃)₂CF(CF₂)₆CH₂CH₂OCOCH═CH₂, (CF₃)₂CF(CF₂)₆CH₂CH₂OCOC(CH₃)═CH₂,CF₃(CF₂)₅CH₂CH₂OCOCH═CH₂, CF₃(CF₂)₅CH₂CH₂OCOC(CH₃)═CH₂,CF₃(CF₂)₇CH₂CH₂OCOCH═CH₂, CF₃(CF₂)₇CH₂CH₂OCOC(CH₃)═CH₂,CF₃(CF₂)₉CH₂CH₂OCOCH═CH₂, CF₃(CF₂)₉CH₂CH₂OCOC(CH₃)═CH₂,H(CF₂)₆CH₂CH₂OCOCH═CH₂, H(CF₂)₈CH₂CH₂OCOC(CH₃)═CH₂,F(CF₂)₈CH₂CH₂OCOCH═CH₂, F(CF₂)₈CH₂CH₂OCOC(CH₃)═CH₂,H(CF₂)₄CH₂OCOC(CH₃)═CH₂, H(CF₂)₄CH₂OCOCH═CH₂, and the like, and one ormore types of compounds selected from the above examples may be combinedand used.

The content ratio (which is a value obtained by substitution with theweight of the monomer used to synthesize the polymer) of thefluoroalkyl- or fluoroaryl-containing vinyl monomer c1 in the polymer Cis preferably 15 to 100 wt %, and more preferably 18 to 100 wt %. Whenthe content ratio of the fluoroalkyl- or fluoroaryl-containing vinylmonomer c1 in the polymer C is within the aforementioned range, thedispersion stability of the pigment in the ink, the discharge stabilityof the ink, and the thermal resistance of the formed colored portion canbe made particularly excellent. The polymer C can also be provided withparticularly excellent compatibility with the polymer A or the polymerB, and the formed colored portion can be provided with particularly hightransparency. In contrast, when the content ratio of the fluoroalkyl- orfluoroaryl-containing vinyl monomer c1 in the polymer C is less than thelower limit of the aforementioned range, the effects of including afluoroalkyl- or fluoroaryl-containing vinyl monomer c1 such as thosedescribed above may not be adequately demonstrated. When the polymer Cis a mixture of a plurality of types of compounds, the weighted averagevalue (weighted average value based on weight ratio) of the mixedcompounds may be used as the content ratio of the fluoroalkyl- orfluoroaryl-containing vinyl monomer c1. When the polymer C is a mixtureof a plurality of types of compounds, the compounds all preferablycontain the fluoroalkyl- or fluoroaryl-containing vinyl monomer c1 insuch a content ratio as described above.

Other Polymerizable Vinyl Monomer c2

The polymer C may contain as a monomer component a polymerizable vinylmonomer c2 other than the fluoroalkyl- or fluoroaryl-containing vinylmonomer c1 such as described above. A vinyl monomer that can becopolymerized with the fluoroalkyl- or fluoroaryl-containing vinylmonomer c1 may be used as the polymerizable vinyl monomer c2, andspecific examples thereof include 2-acryloyloxyethyl isocyanate (productname: Karenz MOI; manufactured by Showa Denko), 2-methacryloyloxyethylisocyanate, and other (meth)acryloyl isocyanates and the like in which(meth)acryloyl is bonded with an isocyanate group via a C₂₋₆ alkylenegroup; 2-(0-[1′-methylpropylideneamino]carboxyamino)ethyl methacrylate(product name: Karenz MOI-BM; manufactured by Showa Denko) and otherpolymerizable vinyl monomers provided with an isocyanate group or ablocked isocyanate group in which the isocyanate group is protected by aprotective group; 2-hydroxyethyl(meth)acrylate,hydroxypropyl(meth)acrylate, 2,3-dihydroxybutyl(meth)acrylate,4-hydroxybutyl(meth)acrylate, 6-hydroxyhexyl(meth)acrylate,8-hydroxyoctyl(meth)acrylate, 4-hydroxymethyl cyclohexyl(meth)acrylate,polyalkylene glycol mono(meth)acrylate, and other monoester compounds ofa polyalcohol and acrylic acid or methacrylic acid; compounds in whichε-caprolactone is ring-open polymerized with the abovementionedmonoester compounds of a polyalcohol and acrylic acid or methacrylicacid (PLACCEL FA series, PLACCEL FM series, and the like manufactured byDaicel Chemical Industries); compounds in which ethylene oxide andpropylene oxide is ring-open polymerized, and other polymerizable vinylmonomers provided with a hydroxyl group; methyl(meth)acrylate,ethyl(meth)acrylate, butyl(meth)acrylate, 2-ethylhexyl(meth)acrylate,phenyl(meth)acrylate, cyclohexyl(meth)acrylate,dicyclopentanyl(meth)acrylate, dicyclopentanyloxyethyl(meth)acrylate,isobornyl(meth)acrylate, benzyl(meth)acrylate, phenylethyl(meth)acrylate, and other C₁₋₁₂ alkyl and aralkyl(meth)acrylates;styrene, α-methylstyrene, and other vinyl aromatic compounds; and one ormore types of compounds selected from the above examples may be combinedand used. However, the polymer C does not contain as a monomer componentthe epoxy-containing vinyl monomer a1 and the alkoxysilyl-containingvinyl monomer b1 such as previously described.

The content ratio (which is a value obtained by substitution with theweight of the monomer used to synthesize the polymer) of thepolymerizable vinyl monomer c2 in the polymer C is preferably 85 wt % orless, and more preferably 82 wt % or less. When the polymer C is amixture of a plurality of types of compounds, the weighted average value(weighted average value based on weight ratio) of the mixed compoundsmay be used as the content ratio of the polymerizable vinyl monomer c2.When the polymer C is a mixture of a plurality of types of compounds,the content ratio of the polymerizable vinyl monomer c2 with respect tothe mixture of compounds preferably satisfies such conditions as thosedescribed above.

When the curable resin material includes the polymer C, the ratio(content ratio) accounted for by the polymer C in the curable resinmaterial is not particularly limited, but is preferably 1 to 20 wt %,and more preferably 2 to 15 wt %. When the polymer C is a mixture of aplurality of types of compounds, the sum of the content ratios of themixed compounds may be used as the content ratio of the polymer C.

When the curable resin material includes the polymer C, the ratio of thepolymer A content and the polymer C content in terms of weight ispreferably 50:50 to 99:1, and more preferably 60:40 to 98:2. Satisfyingsuch conditions enables the ink to be provided with particularlyexcellent dispersion stability of the colorant in the ink, and dischargestability of the ink. The color filter can be provided with particularlyexcellent uniformity of characteristics between individual units, andunevenness of color and saturation between different regions can be moreeffectively prevented. The color filter can also be provided withparticularly excellent durability. Color mixing of the colored portions(inks) between adjacent cells can also be more effectively prevented.

The weight-average molecular weight of each polymer (polymer A, polymerB, polymer C) such as described above is preferably 1000 to 50000, morepreferably 1200 to 10000, and even more preferably 1500 to 5000. Thedegree of dispersion (weight-average molecular weight Mw/number-averagemolecular weight Mn) of each polymer (polymer A, polymer B, polymer C)such as described above is about 1 to 3.

The content ratio of the curable resin material in the color filter inkis preferably 0.5 to 25 wt %, and more preferably 1 to 18 wt %. When thecontent ratio of the curable resin material is within this range, themanufactured color filter can be provided with particularly excellentdurability while the ink is provided with particularly excellentdispersion stability of the pigment in the ink, and particularlyexcellent discharge properties from the droplet discharge head. Adequatecolor saturation can also be maintained in the manufactured colorfilter.

When a pigment is included as the colorant, the content ratio of thecurable resin material with respect to 100 parts by weight of thecolorant is preferably 15 to 50 parts by weight, and more preferably 19to 42 parts by weight. Satisfying such conditions enables the ink to beprovided with particularly excellent dispersion stability of the pigmentin the ink, and discharge stability of the ink, and enables the formedcolored portion of the color filter to be provided with particularlyexcellent contrast and coloration properties. Particularly excellentadhesion of the colored portion to the substrate can also be obtained.

The curable resin material constituting the color filter ink may alsoinclude a polymer other than the polymer A, polymer B, and polymer Cdescribed above.

Colorant

The color filter has colored portions (usually three colorscorresponding to RGB) in a plurality of different colors. The inksconstituting the color filter ink set each include a colorant thatcorresponds to the hue of the colored portion to be formed.

Various organic pigments and various inorganic pigments may be used asthe colorant, but an organic pigment is preferred. The use of an organicpigment enables the colored portion formed using the ink to be providedwith particularly excellent coloration properties, for example. Examplesof organic pigments include compounds classified as pigments in theColor Index (C. I.; issued by The Society of Dyers and Colorists), andmore specifically, compounds such as those below numbered according tothe Color Index (C. I.). Specifically, examples of organic pigmentsinclude C. I. Pigment Yellow 1, 3, 12, 13, 14, 15, 16, 17, 20, 24, 31,34, 35, 35:1, 37, 37:1, 42, 43, 53, 55, 60, 61, 65, 71, 73, 74, 81, 83,93, 94, 95, 97, 98, 100, 101, 104, 106, 108, 109, 110, 113, 114, 116,117, 119, 120, 126, 127, 128, 129, 138, 139, 150, 151, 152, 153, 154,155, 156, 157, 166, 168, 175, 180, 184, and 185; C. I. Pigment Orange 1,5, 13, 14, 16, 17, 20, 20:1, 24, 34, 36, 38, 40, 43, 46, 49, 51, 61, 63,64, 71, 73, and 104; C. I. Pigment Violet 1, 3, 14, 16, 19, 23, 29, 32,36, 38, and 50;C. I. Pigment Red 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,14, 15, 16, 17, 18, 19, 21, 22, 23, 30, 31, 32, 37, 38, 40, 41, 42,48:1, 48:2, 48:3, 48:4, 49:1, 49:2, 50:1, 52:1, 53:1, 57, 57:1, 57:2,58:2, 58:4, 60:1, 63:1, 63:2, 64:1, 81, 81:1, 83, 88, 90:1, 97, 101,102, 104, 105, 106, 108, 108:1, 112, 113, 114, 122, 123, 144, 146, 149,150, 151, 166, 168, 170, 171, 172, 174, 175, 176, 177, 178, 179, 180,185, 187, 188, 190, 193, 194, 202, 206, 207, 208, 209, 215, 216, 220,224, 226, 242, 243, 245, 254, 255, 264, and 265; C. I. Pigment Blue 1,15, 15:1, 15:2, 15:3, 15:4, 15:6, 17:1, 18, 60, 27, 28, 29, 35, 36, 60,and 80; C. I. Pigment Green 7, 36, 15, 17, 18, 19, 26, 50, and 58; C. I.Pigment Brown 7, 11, 23, 25, and 33; C. I. Pigment Black 1 and 7; andderivatives of these pigments and the like, and one or more types ofpigments selected from the above examples may be combined and used.

The ink (red ink) can be provided with particularly excellent colorationproperties particularly when the ink includes C. I. Pigment Red 177 anda derivative thereof, and/or C. I. Pigment Red 254 and a derivativethereof as pigments (red pigments). The effects of joint use with aresin material and dispersing agent such as described in detailhereinafter can also be more significantly demonstrated, andparticularly excellent ink discharge stability and long-term dispersionstability of the pigment particles in the ink can be obtained.

When a compound (derivative) indicated by Formula (4) or Formula (5)below is included as the derivative of C. I. Pigment Red 177 and thederivative of C. I. Pigment Red 254, such effects as those describedabove can be even more significantly demonstrated.

In Formula (4), n is an integer from 1 to 4.

In Formula (5), n is an integer from 1 to 4.

The coloration properties of the ink (green ink) can be madeparticularly excellent particularly when the ink includes C. I. PigmentGreen 58 (brominated zinc phthalocyanine pigment) as a pigment (greenpigment). Although C. I. Pigment Green 58 has the characteristic ofexcellent brightness, the material is conventionally extremely difficultto stably disperse, but in the ink of the present embodiment, thelong-term dispersion stability in the ink can be made particularlyexcellent even when C. I. Pigment Green 58 is included, which isconventionally extremely difficult to stably disperse. When the inkincludes C. I. Pigment Green 58, the ink preferably also includes asulfonated pigment derivative as a secondary pigment. Even moreexcellent coloration properties of the ink can thereby be obtained, andthe ink can be provided with particularly excellent discharge stability.

When C. I. Pigment Green 58 and a sulfonated pigment derivative areincluded as pigments, the ink preferably contains a compound(derivative) indicated by Formula (6) below as the sulfonated pigmentderivative. Particularly excellent droplet discharge stability andlong-term dispersion stability of pigment particles in the ink can beobtained, and an image having more excellent contrast can be displayedin the manufactured color filter. In a method such as describedhereinafter, the fine dispersion step can be performed with particularlyexcellent efficiency, and the ink can be manufactured in a short timeusing a relatively small amount of energy. The ink can therefore beprovided with particularly excellent production properties, which cancontribute to reduced production cost.

In Formula (6), n is an integer from 1 to 5.

The inventors discovered as a result of concentrated investigation thatsuch excellent effects as described above are obtained through the useof a pigment derivative (secondary pigment) having a specific chemicalstructure together with C. I. Pigment Green 58 (main pigment), althoughthe mechanism of these effects is not known in detail, the effects areconsidered to be obtained for such reasons as those described below.

A highly conjugated system is formed by the molecule as a whole in thebrominated phthalocyanine that constitutes C. I. Pigment Green 58, and aplanar structure is energetically stable. Planar molecules of thebrominated phthalocyanine are in a layered (parallel to each other)arrangement, whereby a stable state occurs in which π electrons ofconjugated systems between molecules are overlapped. The C. I. PigmentGreen 58 is therefore easily aggregated, and difficult to stablydisperse in a solvent.

In a pigment derivative such as described above, the hydrogen atombonded to a nitrogen atom in Formula (6) forms a hydrogen bond betweenthe oxygen atoms that form a phthalimide structure. For this reason, thehydrogen atom bonded to a nitrogen atom in Formula (6) substantiallyforms a strong bond with the nitrogen atom forming the quinolinestructure, as well as the oxygen atom forming the phthalimide structure,and in a pigment derivative (sulfonated pigment derivative) such asdescribed above, a stable ring structure (seven-member ring structure)is formed by the seven atoms that are labeled 1 through 7 in Formula(6). A non-parallel state with respect to the plane of the quinolinestructure and the plane of the phthalimide structure occurs through theformation of such a seven-member ring structure.

The plane of the quinoline structure, and the plane of the phthalimidestructure are thus non-parallel, whereby a pigment derivative(sulfonated pigment derivative) having the appropriate degree ofaffinity to C. I. Pigment Green 58 (a brominated phthalocyanine) isintroduced between molecules of C. I. Pigment Green 58, and the C. I.Pigment Green 58, which is originally easily aggregated as describedabove, can be made less prone to aggregate. Furthermore, since a pigmentderivative (sulfonated pigment derivative) such as described above has asulfo group in the molecule thereof, the pigment derivative hasexcellent dispersion properties in the solvent described hereinafter.Such factors as those described above are considered to operatesynergistically to produce such excellent effects as described above.

When C. I. Pigment Green 58 and a pigment derivative (sulfonated pigmentderivative) such as described above are included, the content ratio ofthe pigment derivative (sulfonated pigment derivative) in the ink is notparticularly limited, but is preferably 2 to 32 parts by weight, andmore preferably 7 to 28 parts by weight with respect to 100 parts byweight of C. I. Pigment Green 58 (main pigment). Particularly excellentdischarge stability of droplets and long-term dispersion stability ofthe pigment particles in the ink can thereby be obtained, and the colorfilter formed using the ink can be provided with particularly excellentbrightness and contrast.

The ink (blue ink) can be provided with particularly excellentcoloration properties particularly when the ink includes C. I. PigmentBlue 15:6 or a derivative of C. I. Pigment Blue 15 as the pigment (bluepigment). Particularly excellent ink discharge stability and long-termdispersion stability of the pigment particles in the ink can also beobtained.

The content ratio of the colorant in the ink is preferably 3 to 25 wt %or higher, more preferably 3.5 to 20 wt %, and more preferably 4.0 to9.4 wt %. When the content ratio of the colorant is within theaforementioned range, higher color saturation can be maintained in thecolor filter that is manufactured using the ink, and the color filtercan be used for clearer image display. The amount of the ink that isneeded to form a colored portion having a predetermined color saturationcan also be reduced, which is advantageous from the perspective ofresource saving. Since the amount of evaporation of the solvent can besuppressed during formation of the colored portion of the color filter,the environmental impact can be reduced. In the conventional technique,when the colorant is included in such a relatively high concentration,the discharge stability is particularly low, and flight deflection,instability of the droplet discharge quantity, and other problems occurparticularly easily when droplets of the ink are discharged. Also in theconventional technique, such problems as a severe occurrence of defectsdue to fluctuation of the discharge quantity among different locationson the surface, and marked reduction of production properties of thecolor filter occurs particularly when droplets are discharged onto alarge substrate (e.g., G5 or larger) to form colored portions. In thepresent invention, however, even when the colorant is included at arelatively high concentration, such problems as those described abovecan be reliably prevented from occurring, unevenness of color,saturation, and the like in different locations of the manufacturedcolor filter, or fluctuation of characteristics between individual unitscan be reliably prevented, and a color filter can be manufactured withexcellent productivity, as described in detail hereinafter.Specifically, the effects of the present invention are moresignificantly demonstrated when the ink includes a relatively highconcentration of the colorant, as described above. The durability of themanufactured color filter can also be made particularly excellent.

The average grain size of the pigment particles (colorant particles) inthe ink is not particularly limited, but is preferably 10 to 200 nm, andmore preferably 20 to 180 nm. The dispersion stability of the pigment inthe ink, as well as the contrast and other characteristics in the colorfilter can thereby be made particularly excellent while making the lightfastness of the color filter manufactured using the ink adequatelysuperior.

Solvent

Besides the components described above, a solvent may be included in theink.

The solvent functions as a dispersion medium for dispersing the colorantin the ink. In a ink manufacturing method such as the one describedhereinafter, the solvent usually functions as a medium for dissolving aresin material such as described above in a liquid dispersion. Most ofthe solvent (dispersion medium) constituting the ink is usually removedin the process of manufacturing the color filter.

Ester compounds, ether compounds, hydroxyketones, carbonic diesters,cyclic amide compounds, and the like, for example, may be used as thesolvent, preferred among which are (1) ethers (polyalcohol ethers) ascondensates of polyalcohols (e.g., ethylene glycol, propylene glycol,butylene glycol, glycerin, and the like); alkyl ethers (e.g., methylether, ethyl ether, butyl ether, hexyl ether, and the like) ofpolyalcohols or polyalcohol ethers; and esters (e.g., formate, acetate,propionate, and the like); (2) esters (e.g., methyl esters and the like)of polycarboxylic acids (e.g., succinic acid, glutamic acid, and thelike); (3) ethers, esters, and the like of compounds (hydroxy acids)having at least one hydroxyl group and at least one carboxyl group inthe molecule thereof; and (4) carbonic diesters having a chemicalstructure such as that obtained by reaction of a polyalcohol and aphosgene. Examples of compounds that can be used as the solvent include2-(2-methoxy-1-methylethoxy)-1-methyl ethyl acetate, triethylene glycoldimethyl ether, triethylene glycol diacetate, diethylene glycolmonoethyl ether acetate, 4-methyl-1,3-dioxolan-2-one,bis(2-butoxyethyl)ether, dimethyl glutarate, ethylene glycoldi-n-butyrate, 1,3-butylene glycol diacetate, diethylene glycolmonobutyl ether acetate, tetraethylene glycol dimethyl ether,1,6-diacetoxyhexane, tripropylene glycol monomethyl ether,butoxypropanol, diethylene glycol methyl ethyl ether, diethylene glycolmethyl butyl ether, triethylene glycol methyl ethyl ether, triethyleneglycol methyl butyl ether, dipropylene glycol monomethyl ether acetate,diethylene glycol dimethyl ether, ethyl 3-ethoxy propionate, diethyleneglycol ethyl methyl ether, 3-methoxybutyl acetate, diethylene glycoldiethyl ether, ethyl octanoate, ethylene glycol monobutyl ether acetate,ethylene glycol monobutyl ether, cyclohexyl acetate, diethyl succinate,ethylene glycol diacetate, propylene glycol diacetate,4-hydroxy-4-methyl-2-pentanone, dimethyl succinate, 1-butoxy-2-propanol,diethylene glycol monoethyl ether, diethylene glycol monomethyl ether,dipropylene glycol monomethyl ether, 3-methoxy-n-butyl acetate,diacetin, dipropylene glycol mono n-propyl ether, polyethylene glycolmonomethyl ether, butyl glycolate, ethylene glycol monohexyl ether,dipropylene glycol mono n-butyl ether, N-methyl-2-pyrrolidone,triethylene glycol butyl methyl ether, bis(2-propoxyethyl)ether,diethylene glycol diacetate, diethylene glycol butyl methyl ether,diethylene glycol butyl ethyl ether, diethylene glycol butyl propylether, diethylene glycol ethyl propyl ether, diethylene glycol methylpropyl ether, diethylene glycol propyl ether acetate, triethylene glycolmethyl ether acetate, triethylene glycol ethyl ether acetate,triethylene glycol propyl ether acetate, triethylene glycol butyl etheracetate, triethylene glycol butyl ethyl ether, triethylene glycol ethylmethyl ether, triethylene glycol ethyl propyl ether, triethylene glycolmethyl propyl ether, dipropylene glycol methyl ether acetate, n-nonylalcohol, diethylene glycol monobutyl ether, triethylene glycolmonomethyl ether, ethylene glycol 2-ethylhexyl ether, triethylene glycolmonoethyl ether, diethylene glycol monohexyl ether, triethylene glycolmonobutyl ether, diethylene glycol mono-2-ethylhexyl ether, tripropyleneglycol mono n-butyl ether, butyl cellosolve acetate, and the like, andone or more types of compounds selected from the above examples may becombined and used. Among these examples, the solvent preferably includesone or more types of compounds selected from the group that includes1,3-butylene glycol diacetate, bis(2-butoxyethyl)ether, and diethyleneglycol monobutyl ether acetate. The ink can thereby be provided withparticularly excellent droplet discharge stability. As a result, colormixing of the colored portions (inks) between adjacent cells can be moreeffectively prevented. Unevenness of color, saturation, and the like inregions of the manufactured color filter can be more effectivelysuppressed, and the color filter can be provided with particularlyexcellent uniformity of characteristics between individual units. Whenthe ink includes a pigment as the colorant, particularly excellentlong-term dispersion stability of the pigment particles in the ink canbe obtained. Adequately excellent long-term dispersion stability of thepigment can also be obtained even when the content ratio of the pigmentin the ink is high. When the solvent is composed of a compound such asdescribed above, particularly excellent discharge stability of dropletscan be obtained, the dispersion stability of the pigment particles inthe ink can be made particularly excellent, and the ink can be providedwith particularly excellent long-term storage properties. When thesolvent is composed of a compound such as described above, the ink canbe reliably made to spread into the entire cell in the method formanufacturing a color filter such as described hereinafter, and theeffects of providing the landing prohibition region can be moresignificantly demonstrated. A flattened colored portion can easily beformed even when the conditions for removing the solvent are notstrictly prescribed. In other words, the internal shape of the pixels iseasily controlled during baking.

The boiling point of the solvent at atmospheric pressure (1 atm) ispreferably 160 to 300° C., more preferably 180 to 290° C., and even morepreferably 200 to 280° C. When the boiling point of the solvent atatmospheric pressure is within this range, blockage and the like in thedroplet discharge head for discharging the ink can be more effectivelyprevented, and the color filter can be manufactured with particularlyexcellent productivity.

The vapor pressure of the solvent at 25° C. is preferably 0.7 mmHg orlower, and more preferably 0.1 mmHg or lower. When the vapor pressure ofthe solvent is within this range, blockage and the like in the dropletdischarge head for discharging the ink can be more effectivelyprevented, and the color filter can be manufactured with particularlyexcellent productivity.

The content ratio of the solvent in the ink is preferably 50 to 98 wt %,more preferably 70 to 95 wt %, and even more preferably 80 to 93 wt %.When the content ratio of the solvent is within this range, themanufactured color filter can be provided with excellent durabilitywhile the discharge properties of the ink from the droplet dischargehead are made particularly excellent. Adequate color saturation can alsobe maintained in the manufactured color filter.

Dispersing Agent

A dispersing agent may be included in the ink. Particularly excellentdispersion stability and dispersion properties of the pigment in the inkcan thereby be obtained when the ink includes a pigment as the colorant,for example. Through the use of the dispersing agent, the dispersingagent adheres to (adsorbs on) the surfaces of the pigment particles(pigment particles having a relatively large grain size that are notfine dispersed) added to the dispersing-agent-dispersed liquid in thefine dispersion step of the manufacturing method such as describedhereinafter, and excellent dispersion properties of the pigmentparticles (pigment particles having a relatively large grain size thatare not fine dispersed) in the dispersing-agent-dispersed liquid can beobtained. The fine dispersion process in the fine dispersion step canthereby be efficiently performed, the production properties of the inkcan be made particularly excellent, particularly excellent long-termdispersion stability of the pigment particles (fine dispersed pigmentfine-particles) can be obtained in the color filter ultimately obtained,and the color filter manufactured using the ink can be provided withparticularly excellent brightness and contrast.

The dispersing agent is not particularly limited, but a polymer-baseddispersing agent, for example, may be used. Examples of polymer-baseddispersing agents include basic polymer-based dispersing agents, neutralpolymer-based dispersing agents, acidic polymer-based dispersing agents,and the like. Examples of such polymer-based dispersing agents includedispersing agents composed of acrylic-based and modified acrylic-basedcopolymers; urethane-based dispersing agents; and dispersing agentscomposed of polyaminoamide salts, polyether esters, phosphoric acidester-based compounds, aliphatic polycarboxylic acids, and the like.

More specific examples of dispersing agents include Disperbyk 101,Disperbyk 102, Disperbyk 103, Disperbyk P104, Disperbyk P104S, Disperbyk220S, Disperbyk 106, Disperbyk 108, Disperbyk 109, Disperbyk 110,Disperbyk 111, Disperbyk 112, Disperbyk 116, Disperbyk 140, Disperbyk142, Disperbyk 160, Disperbyk 161, Disperbyk 162, Disperbyk 163,Disperbyk 164, Disperbyk 166, Disperbyk 167, Disperbyk 168, Disperbyk170, Disperbyk 171, Disperbyk 174, Disperbyk 180, Disperbyk 182,Disperbyk 183, Disperbyk 184, Disperbyk 185, Disperbyk 2000, Disperbyk2001, Disperbyk 2050, Disperbyk 2070, Disperbyk 2095, Disperbyk 2150,Disperbyk LPN6919, Disperbyk 9075, and Disperbyk 9077 (all manufacturedby Byk Chemie Japan); EFKA 4008, EFKA 4009, EFKA 4010, EFKA 4015, EFKA4020, EFKA 4046, EFKA 4047, EFKA 4050, EFKA 4055, EFKA 4060, EFKA 4080,EFKA 4400, EFKA 4401, EFKA 4402, EFKA 4403, EFKA 4406, EFKA 4408, EFKA4300, EFKA 4330, EFKA 4340, EFKA 4015, EFKA 4800, EFKA 5010, EFKA 5065,EFKA 5066, EFKA 5070, EFKA 7500, and EFKA 7554 (all manufactured by CibaSpecialty Chemicals); Solsperse 3000, Solsperse 9000, Solsperse 13000,Solsperse 16000, Solsperse 17000, Solsperse 18000, Solsperse 20000,Solsperse 21000, Solsperse 24000, Solsperse 26000, Solsperse 27000,Solsperse 28000, Solsperse 32000, Solsperse 32500, Solsperse 32550,Solsperse 33500 Solsperse 35100, Solsperse 35200, Solsperse 36000,Solsperse 36600, Solsperse 38500, Solsperse 41000, Solsperse 41090, andSolsperse 20000 (all manufactured by Nippon Lubrizol); Ajisper PA111,Ajisper PB711, Ajisper PB821, Ajisper PB822, and Ajisper PB824 (allmanufactured by Ajinomoto Fine-Techno); Disparlon 1850, Disparlon 1860,Disparlon 2150, Disparlon 7004, Disparlon DA-100, Disparlon DA-234,Disparlon DA-325, Disparlon DA-375, Disparlon DA-705, Disparlon DA-725,and Disparlon PW-36 (all manufactured by Kusumoto Chemicals); FlorenDOPA-14, Floren DOPA-15B, Floren DOPA-17, Floren DOPA-22, FlorenDOPA-44, Floren TG-710, and Floren D-90 (all manufactured by KyoeiKagaku); Anti-Terra-205 (manufactured by Byk Chemie Japan); and thelike, and one or more types of compounds selected from the aboveexamples may be combined and used.

The joint use of a dispersing agent having a predetermined acid value(also referred to hereinafter as an acid-value dispersing agent) and adispersing agent having a predetermined amine value (also referred tohereinafter as an amine-value dispersing agent) as dispersing agents isparticularly preferred. The effects of an acid-value dispersing agentfor demonstrating viscosity-reducing effects whereby the viscosity ofthe ink is reduced, and the effects of an amine-value dispersing agentwhereby the viscosity of the color filter ink (first ink) is stabilizedcan thereby be obtained at the same time, and particularly excellentdispersion stability of the pigment in the ink can be obtained. Inparticular, a method such as the one described hereinafter has apreparatory dispersion step for obtaining a dispersing-agent-dispersedliquid in which the dispersing agent is dispersed in a solvent bystirring a mixture of the dispersing agent, a thermoplastic resin, andthe solvent prior to performing the pigment fine dispersion process, butin such a method, the joint use of an acid-value dispersing agent and anamine-value dispersing agent makes it possible to reliably preventassociation of the dispersing agents (association of the acid-valuedispersing agent and the amine-value dispersing agent), and to obtainparticularly excellent dispersion stability of the pigment such asdescribed above.

Specific examples of acid-value dispersing agents include DisperbykP104, Disperbyk P104S, Disperbyk 220S, Disperbyk 110, Disperbyk 111,Disperbyk 170, Disperbyk 171, Disperbyk 174, and Disperbyk 2095 (allmanufactured by Byk Chemie Japan); EFKA 5010, EFKA 5065, EFKA 5066, EFKA5070, EFKA 7500, and EFKA 7554 (all manufactured by Ciba SpecialtyChemicals); Solsperse 3000, Solsperse 16000, Solsperse 17000, Solsperse18000, Solsperse 36000, Solsperse 36600, and Solsperse 41000 (allmanufactured by Nippon Lubrizol); and the like.

Specific examples of amine-value dispersing agents include Disperbyk102, Disperbyk 160, Disperbyk 161, Disperbyk 162, Disperbyk 163,Disperbyk 164, Disperbyk 166, Disperbyk 167, Disperbyk 168, Disperbyk2150, Disperbyk LPN6919, Disperbyk 9075, and Disperbyk 9077 (allmanufactured by Byk Chemie Japan); EFKA 4015, EFKA 4020, EFKA 4046, EFKA4047, EFKA 4050, EFKA 4055, EFKA 4060, EFKA 4080, EFKA 4300, EFKA 4330,EFKA 4340, EFKA 4400, EFKA 4401, EFKA 4402, EFKA 4403, and EFKA 4800(all manufactured by Ciba Specialty Chemicals); Ajisper PB711(manufactured by Ajinomoto Fine Techno); Anti-Terra-205 (manufactured byByk Chemie Japan); and the like.

When an acid-value dispersing agent and an amine-value dispersing agentare used jointly, the acid value (acid value on a solid basis) of theacid-value dispersing agent is not particularly limited, but ispreferably 5 to 370 KOH mg/g, more preferably 20 to 270 KOH mg/g, andmore preferably 30 to 135 KOH mg/g. When the acid value of theacid-value dispersing agent is within the aforementioned range, thedispersion stability of the pigment can be particularly excellent in thecase of joint use with an amine-value dispersing agent. The acid valueof the dispersing agent can be calculated by a method based on DIN ENISO 2114, for example.

The acid-value dispersing agent is preferably one having a predeterminedamine value, i.e., an amine value of zero.

When an amine-value dispersing agent and an acid-value dispersing agentare used jointly, the amine value (amine value on a solid basis) of theamine-value dispersing agent is not particularly limited, but ispreferably 5 to 200 KOH mg/g, more preferably 25 to 170 KOH mg/g, andmore preferably 30 to 130 KOH mg/g. When the amine value of theamine-value dispersing agent is within the aforementioned range, thedispersion stability of the pigment can be particularly excellent in thecase of joint use with an amine-value dispersing agent. The amine valueof the dispersing agent can be calculated by a method based on DIN16945, for example.

The amine-value dispersing agent is preferably one having apredetermined acid value, i.e., an acid value of zero.

When an acid-value dispersing agent and an amine-value dispersing agentare used jointly, it is preferred that the relation 0.1≦X_(A)/X_(B)≦1 besatisfied, and more preferred that the relation 0.15≦X_(A)/X_(B)≦0.5 besatisfied, wherein X_(A) (wt %) is the content ratio of the acid-valuedispersing agent in the ink, and X_(B) (wt %) is the content ratio ofthe amine-value dispersing agent in the ink. By satisfying such arelation, the synergistic effects of jointly using an acid-valuedispersing agent and an amine-value dispersing agent are moresignificantly demonstrated, and particularly excellent pigmentdispersion stability, droplet discharge stability, and othercharacteristics can be obtained.

It is also preferred that the relation 0.01≦(AV×X_(A))/(BV×X_(B))≦1.9 besatisfied, and more preferred that the relation0.10≦(AV×X_(A))/(BV×X_(B))≦0.95 be satisfied, wherein AV (KOHmg/g) isthe acid value of the acid-value dispersing agent, BV (KOHmg/g) is theamine value of the amine-value dispersing agent, X_(A) (wt %) is thecontent ratio of the acid-value dispersing agent, and X_(B) (wt %) isthe content ratio of the amine-value dispersing agent. By satisfyingsuch a relation, the synergistic effects of jointly using an acid-valuedispersing agent and an amine-value dispersing agent are moresignificantly demonstrated, and particularly excellent pigmentdispersion stability, droplet discharge stability, and othercharacteristics can be obtained.

The content ratio of the dispersing agent in the ink is not particularlylimited, but is preferably 2.5 to 10.2 wt %, and more preferably 3.2 to9.2 wt %.

Other Components

Besides the abovementioned components, the ink may include athermoplastic resin. Particularly excellent dispersion properties of thepigment particles in the ink can thereby be obtained. Extremelyexcellent dispersion stability of the pigment particles in the ink canbe obtained particularly through the use of a thermoplastic resin in thepreparatory dispersion step in the manufacturing method such asdescribed hereinafter.

Examples of thermoplastic resins include alginic acid, polyvinylalcohol, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethylcellulose, methyl cellulose, styrene-acrylic acid resin, styrene-acrylicacid-acrylic acid ester resin, styrene-maleic acid resin, styrene-maleicacid semi-ester resin, methacrylic acid-methacrylic acid ester resin,acrylic acid-acrylic acid ester resin, isobutylene-maleic acid resin,rosin-modified maleic acid resin, polyvinyl pyrrolidone, gum arabicstarch, polyallyl amine, polyvinyl amine, polyethylene imine, and thelike, and one or more types of compounds selected from the aboveexamples may be combined and used.

The content ratio of the thermoplastic resin in the color filter ink isnot particularly limited, but is preferably 1.5 to 7.7 wt %, and morepreferably 2.1 to 7.2 wt %.

The ink of the present invention may include components other than thosedescribed above. Examples of such components include various dyes;various cross-linking agents; thermoacid generators such as diazoniumsalt, iodonium salt, sulfonium salt, phosphonium salt, selenium salt,oxonium salt, ammonium salt, benzothiazolium salt, and other oniumsalts; diazonium salt, iodonium salt, sulfonium salt, phosphonium salt,selenium salt, oxonium salt, ammonium salt, and other photoacidgenerators; various polymerization initiators; acid crosslinking agents;intensifiers; photostabilizers; adhesive improvers; variouspolymerization accelerants; various photostabilizers; glass, alumina,and other fillers; vinyl trimethoxysilane, vinyl triethoxysilane, vinyltris(2-methoxy ethoxy)silane, N-(2-aminoethyl)-3-aminopropyl methyldimethoxysilane, N-(2-aminoethyl)-3-aminopropyl trimethoxysilane,3-aminopropyl triethoxysilane, 3-glycidoxy propyl trimethoxysilane,3-glycidoxy propyl methyl dimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-chloro propyl methyl dimethoxysilane, 3-chloropropyl trimethoxysilane, 3-methacryloxy propyl trimethoxysilane,3-mercapto propyl trimethoxysilane, and other adhesion accelerants;2,2-thiobis(4-methyl-6-t-butyl phenol), 2,6-di-t-butyl phenol, and otherantioxidants; 2-(3-t-butyl-5-methyl-2-hydroxy phenyl)-5-chlorobenzotriazole, alkoxy benzophenone, and other UV absorbers; sodiumpolyacrylate, and other anti-coagulants; and the like.

Examples of dyes include azo dyes, anthraquinone dyes, condensedmulti-ring aromatic carbonyl dyes, indigoid dyes, carbonium dyes,phthalocyanine dyes, methines, polymethine dyes, and the like. Specificexamples of dyes include C. I. Direct Red 2, 4, 9, 23, 26, 28, 31, 39,62, 63, 72, 75, 76, 79, 80, 81, 83, 84, 89, 92, 95, 111, 173, 184, 207,211, 212, 214, 218, 221, 223, 224, 225, 226, 227, 232, 233, 240, 241,242, 243, and 247; C. I. Acid Red 35, 42, 51, 52, 57, 62, 80, 82, 111,114, 118, 119, 127, 128, 131, 143, 145, 151, 154, 157, 158, 211, 249,254, 257, 261, 263, 266, 289, 299, 301, 305, 319, 336, 337, 361, 396,and 397; C. I. Reactive Red 3, 13, 17, 19, 21, 22, 23, 24, 29, 35, 37,40, 41, 43, 45, 49, and 55; C. I. Basic Red 12, 13, 14, 15, 18, 22, 23,24, 25, 27, 29, 35, 36, 38, 39, 45, and 46; C. I. Direct Violet 7, 9,47, 48, 51, 66, 90, 93, 94, 95, 98, 100, and 101; C. I Acid Violet 5, 9,11, 34, 43, 47, 48, 51, 75, 90, 103, and 126; C. I. Reactive Violet 1,3, 4, 5, 6, 7, 8, 9, 16, 17, 22, 23, 24, 26, 27, 33, and 34; C. I. BasicViolet 1, 2, 3, 7, 10, 15, 16, 20, 21, 25, 27, 28, 35, 37, 39, 40, and48; C. I. Direct Yellow 8, 9, 11, 12, 27, 28, 29, 33, 35, 39, 41, 44,50, 53, 58, 59, 68, 87, 93, 95, 96, 98, 100, 106, 108, 109, 110, 130,142, 144, 161, and 163; C. I. Acid Yellow 17, 19, 23, 25, 39, 40, 42,44, 49, 50, 61, 64, 76, 79, 110, 127, 135, 143, 151, 159, 169, 174, 190,195, 196, 197, 199, 218, 219, 222, and 227; C. I. Reactive Yellow 2, 3,13, 14, 15, 17, 18, 23, 24, 25, 26, 27, 29, 35, 37, 41, and 42; C. I.Basic Yellow 1, 2, 4, 11, 13, 14, 15, 19, 21, 23, 24, 25, 28, 29, 32,36, 39, and 40; C. I. Acid Green 16; C. I. Acid Blue 9, 45, 80, 83, 90and 185; C. I. Basic Orange 21 and 23; and the like.

Examples of cross-linking agents that may be used include polycarboxylicacid anhydrides, polycarboxylic acids, polyfunctional epoxy monomers,polyfunctional acrylic monomers, polyfunctional vinyl ether monomers,and polyfunctional oxetane monomers. Specific examples of polycarboxylicacid anhydrides include phthalic anhydride, itaconic anhydride, succinicanhydride, citraconic anhydride, dodecenyl succinic anhydride,tricarballylic anhydride, maleic anhydride, hexahydrophthalic anhydride,dimethyl tetrahydrophthalic anhydride, himic anhydride, nadic anhydride,and other aliphatic or alicyclic dicarboxylic anhydrides; 1,2,3,4-butanetetracarboxylic acid dianhydride and cyclopentane tetracarboxylic aciddianhydride; benzophenone tetracarboxylic anhydride and other aromaticpolycarboxylic acid anhydrides; ethylene glycol bis trimellitate,glycerin tris trimellitate, and other ester-containing organicanhydrides, among which an aromatic polycarboxylic acid anhydride ispreferred. An epoxy resin curing agent composed of a commerciallyavailable carboxylic acid anhydride can also be suitably used. Specificexamples of polycarboxylic acids include succinic acid, glutaric acid,adipic acid, butane tetracarboxylic acid, maleic acid, itaconic acid,and other aliphatic polycarboxylic acids; hexahydrophthalic acid,1,2-cyclohexane dicarboxylic acid, 1,2,4-cyclohexane tricarboxylic acid,cyclopentane tetracarboxylic acid, and other aliphatic polycarboxylicacids; and phthalic acid, isophthalic acid, terephthalic acid,pyromellitic acid, trimellitic acid, 1,4,5,8-naphthalene tetracarboxylicacid, benzophenone tetracarboxylic acid, and other aromaticpolycarboxylic acid, but among these, aromatic polycarboxylic acid ispreferred. Specific examples of a polyfunctional epoxy monomer includethe product name Celloxide 2021 manufactured by Daicel ChemicalIndustries, the product name Epolead GT401 manufactured by DaicelChemical Industries, the product name Epolead PB3600 manufactured byDaicel Chemical Industries, bisphenol A, hydrogenated bisphenol A, andtriglycidyl isocyanurate. Specific example of a polyfunctional acrylicmonomer include pentaerythritolethoxy tetraacrylate, pentaerythritoltetraacrylate, pentaerythritol triacrylate, pentaerythritolethoxytetraacrylate, ditrimethylolpropane tetraacrylate, trimethylolpropanetriacrylate, trimethylolpropane ethoxy triacrylate, dipentaerythritolhexaacrylate trimethallyl isocyanurate, and triallyl isocyanurate.Examples of a polyfunctional vinyl ether monomer include 1,4-butanediolvinyl ether, 1,6-hexanediol divinyl ether, nonanediol divinyl ether,cyclohexanediol divinyl ether, cyclohexanedimethanol divinyl ether,triethylene glycol divinyl ether, trimethylolpropane trivinyl ether, andpentaerythritol tetravinyl ether. Examples of polyfunctional oxetanemonomers include xylylene dioxetane, biphenyl-type oxetane, andnovolac-type oxetane.

The thermoacid generator is a component for generating acid by applyingheat, and particularly preferred among those described above aresulfonium salt and benzothiazolium. More specific examples of thermoacidgenerators in terms of product names include Sunaid SI-45, Sunaid SI-47,Sunaid SI-60, Sunaid SI-60L, Sunaid SI-80, Sunaid SI-80L, Sunaid SI-100,Sunaid SI-100L, Sunaid SI-145, Sunaid SI-150, Sunaid SI-160, SunaidSI-110L, Sunaid SI-180L (all product names, manufactured by SanshinChemical Industry Co., Ltd.), CI-2921, CI-2920, CI-2946, CI-3128,CI-2624, CI-2639, CI-2064 (all product names, manufactured by NipponSoda Co., Ltd.), CP-66, CP-77 (product names, manufactured by AdekaCorporation), and FC-520 (product name, manufactured by 3M Company).

The photoacid generator is a component for generating acid by usinglight, and more specific examples include the product names CyracureUVI-6970, Cyracure UVI-6974, Cyracure UVI-6990, Cyracure UVI-950 (allproduct names, manufactured by US Union Carbide), Irgacure 261 (productname, Ciba Specialty Chemicals), SP-150, SP-151, SP-170, OptomerSP-171(all product names, manufactured by Adeka Corporation), CG-24-61(product name, manufactured by Ciba Specialty Chemicals), Daicat II(product name, manufactured by Daicel Chemical Industries, Ltd.), UVAC1591 (product name, manufactured by Daicel UCB Co., Ltd.), CI-2064,CI-2639, CI-2624, CI-2481, CI-2734, CI-2855, CI-2823, CI-2758 (productname, manufactured by Nippon Soda Co., Ltd.), PI-2074 (product name,manufactured by Rhone Poulenc, pentafluorophenyl borate tolyl cumyliodonium), FFC509 (product name, manufactured by 3M Company), BBI-102,BBI-101, BBI-103, MPI-103, TPS-103, MDS-103, DTS-103, NAT-103, NDS-103(product name, manufactured by Midori Kagaku Co., Ltd.), and CD-1012(product name, manufactured by Sartomer Co., Inc.).

The viscosity (viscosity (kinetic viscosity) measured using an E-typeviscometer) at 25° C. of the ink used to manufacture the color filter ispreferably 13 mPa·s or lower, more preferably 12 mPa·s or lower, andmore preferably 5 to 11 mPa·s. When the viscosity (kinetic viscosity) ofthe ink is thus adequately low, the ink can be more reliably made tospread into the entire cell while color mixing of the colored portions(inks) between adjacent cells is effectively prevented. The productionefficiency (efficiency of forming the colored portion) of the colorfilter can also be made particularly excellent, for example, andunwanted fluctuation of the thickness and other characteristics of thecolored portion can be effectively prevented. Measurement of theviscosity (kinetic viscosity) of the ink can be performed using anE-type viscometer (e.g., RE-01 manufactured by Toki Sangyo), forexample, particularly in accordance with JIS Z8809.

The amount of change in the viscosity at 25° C. of the ink after the inkis left for 7 days at 65° C. is preferably 0.5 mPa·s or less, morepreferably 0.3 mPa·s or less, and more preferably 0.2 mPa·s or less. Thecolor filter ink can thereby be provided with particularly excellentdischarge stability, and the color filter ink can be suitably used for alonger period of time to manufacture a color filter in which theoccurrence of uneven color, saturation, and the like is reliablyprevented.

The contact angle of the ink droplets with respect to the bottom surface(substrate) in the cell is preferably 60° or less, and more preferably55° or less. The ink can thereby be more reliably made to spread intothe entire cell while color mixing of the colored portions (inks)between adjacent cells is effectively prevented. In the presentspecification, the contact angle can be calculated based on JIS K 3257.The contact angle of the ink with respect to the bottom surface(substrate) can be calculated using the ink and a flat plate composed ofthe same material as the substrate.

Color Filter Ink Manufacturing Method

Preferred embodiments of the method for manufacturing a color filter inksuch as described above will next be described.

The manufacturing method of the present embodiment has a preparatorydispersion step of obtaining a dispersing-agent-dispersed liquid inwhich a dispersing agent is dispersed in a solvent, by stirring amixture of a dispersing agent, a thermoplastic resin, and a solvent; afine dispersion step of adding a pigment (colorant) to thedispersing-agent-dispersed liquid, adding inorganic beads in multi-stagefashion and performing a fine dispersion process, and obtaining apigment dispersion; and a curable resin mixing step of mixing thepigment dispersion and the curable resin material.

Preparatory Dispersion Step

In the preparatory dispersion step, a dispersing-agent-dispersed liquidin which a dispersing agent is dispersed in a solvent is prepared bystirring a mixture that includes a dispersing agent, a thermoplasticresin, and a solvent. The associated state of the dispersing agent canthereby be released (undone).

By thus pre-dispersing a mixture that does not include a pigment priorto the process described in detail hereinafter for fine dispersing thepigment in the present embodiment, a color filter ink can ultimately beobtained that has particularly excellent discharge stability, in whichthe pigment particles are uniformly and stably dispersed.

In this step, the thermoplastic resin, the dispersing agent, and thesolvent are mixed together in advance, whereby the dispersing agent andthe thermoplastic resin are adhered to the surfaces of the pigmentparticles (pigment particles having a relatively large grain size thatare not fine dispersed) added to the dispersing-agent-dispersed liquidin the fine dispersion step described hereinafter, and excellentdispersion properties of the pigment particles (pigment particles havinga relatively large grain size that are not fine dispersed) in thedispersing-agent-dispersed liquid can be obtained. The fine dispersionprocess in the fine dispersion step can thereby be efficientlyperformed, the production properties of the ink can be made particularlyexcellent, particularly excellent long-term dispersion stability of thepigment particles (fine dispersed pigment fine-particles) and dischargestability of droplets can be obtained, and the effects of providing thelanding prohibition region can be more significantly demonstrated in theink ultimately obtained.

The content ratio (sum of the content ratios when a plurality of typesof dispersing agents is used jointly) of the dispersing agent in thedispersing-agent-dispersed liquid prepared in the present step is notparticularly limited, but is preferably 10 to 40 wt %, and morepreferably 12 to 32 wt %. When the content ratio of the dispersing agentis within this range, such effects as previously described aredemonstrated more significantly.

The content ratio of the thermoplastic resin in thedispersing-agent-dispersed liquid prepared in the present step is notparticularly limited, but is preferably 6 to 30 wt %, and morepreferably 8 to 26 wt %. When the content ratio of the thermoplasticresin is within this range, such effects as previously described aredemonstrated more significantly.

The content ratio of the solvent in the dispersing-agent-dispersedliquid prepared in the present step is not particularly limited, but ispreferably 40 to 80 wt %, and more preferably 53 to 75 wt %. When thecontent ratio of the solvent is within this range, such effects aspreviously described are demonstrated more significantly.

In the present step, a dispersing-agent-dispersed liquid is obtained bystirring a mixture of the abovementioned components using various typesof agitators.

Examples of agitators that can be used in the present step include aDispermill or other single-shaft or twin-shaft mixer or the like.

The stirring time for which the agitator is used is not particularlylimited, but is preferably 1 to 30 minutes, and more preferably 3 to 20minutes. The associated state of the dispersing agent can thereby bemore effectively released while adequately excellent productionproperties of the color filter ink are obtained, the ink ultimatelyobtained can be provided with particularly excellent dispersionstability of pigment particles and particularly excellent dischargestability, and the effects of providing the landing prohibition regioncan be more significantly demonstrated.

The speed of the stirring vanes of the agitator in the present step isnot particularly limited, but is preferably 500 to 4000 rpm, and morepreferably 800 to 3000 rpm. The associated state of the dispersing agentcan thereby be more effectively released while adequately excellentproduction properties of the ink are obtained, and it is possible toobtain particularly excellent dispersion stability of pigment particlesin the ink ultimately obtained. Degradation, denaturation, and the likeof the thermoplastic resin and other components due to heat and the likecan also be reliably prevented.

Fine Dispersion Step

A pigment such as described above is then added to thedispersing-agent-dispersed liquid obtained in the step described above,inorganic beads are added in multiple stages, and a fine dispersionprocess is performed (fine dispersion step).

Prior to adding the pigment, a preparatory dispersion step such as theone described above is thus provided in the present embodiment, andinorganic beads are added in multiple stages in the step (finedispersion step) of fine dispersing the pigment. In the fine dispersionstep, adding the inorganic beads in multi-stage fashion makes itpossible to form fine-particles of the pigment with superior efficiency,and to make the pigment particles adequately small in the ink ultimatelyobtained. In particular, the effects of jointly using a halogenatedphthalocyanine zinc complex (main pigment) and a sulfonated pigmentderivative (secondary pigment) such as described above, and the effectsof using a method having a preparatory dispersion step and a multi-stagefine dispersion step act synergistically, the ink ultimately obtainedcan be provided with extremely excellent dispersion stability of pigmentand discharge stability of droplets, and the ink can be used tomanufacture a color filter having extremely excellent brightness andcontrast.

In contrast, when the fine dispersion step is not performed in multiplestages, it is difficult to make the pigment particles adequately smallin the ink ultimately obtained, and the production properties of the inkcan be severely reduced. Even when the fine dispersion step is performedin multiple stages, such problems as the following can occur when thepreparatory dispersion step such as described above is omitted.Specifically, when the preparatory dispersion step is omitted, since theassociated state of the dispersing agent is not adequately released (notundone) when the pigment is added, it is difficult to uniformly adherethe dispersing agent and the thermoplastic resin to the surfaces of thepigment particles in the fine dispersion step. It is also difficultobtain adequately excellent dispersion properties of the pigmentparticles (pigment particles having relatively large grain size that arenot fine dispersed) in the solvent in the fine dispersion step.

It is sufficient for the present step to be performed by adding theinorganic beads in multiple stages, and the inorganic beads may be addedin three or more stages, but the inorganic beads are preferably added intwo stages. The production properties of the ink can thereby be madeparticularly excellent while the ink ultimately obtained is providedwith adequately excellent long-term dispersion stability of the pigmentparticles.

A method for adding the inorganic beads in two stages will be describedbelow. Specifically, a typical example of a method will be described forperforming a first treatment using first organic beads, and a secondtreatment using second organic beads in the fine dispersion step.

The inorganic beads (first inorganic beads and second inorganic beads)used in the present step may be composed of any material insofar as thematerial is an inorganic material, but preferred examples of theinorganic beads include zirconia beads (e.g., Toray Ceram grinding balls(trade name); manufactured by Toray) and the like.

First Treatment

In the present step, the pigments (main pigment and secondary pigment)are first added to the dispersing-agent-dispersed liquid prepared in thepreparatory dispersion step described above, and a first treatment isperformed for primary fine dispersion using first inorganic beads havinga predetermined grain size.

The first inorganic beads used in the first treatment preferably have alarger grain size than the second inorganic beads used in the secondtreatment. The efficiency of fine-particle formation (fine dispersion)of the pigments in the overall fine dispersion step can thereby be madeparticularly excellent.

The average grain size of the first inorganic beads is not particularlylimited, but is preferably 0.5 to 3.0 mm, more preferably 0.5 to 2.0 mm,and more preferably 0.5 to 1.2 mm. When the average grain size of thefirst inorganic beads is within the aforementioned range, the efficiencyof fine-particle formation (fine dispersion) of the pigments in theoverall fine dispersion step can be made particularly excellent. Incontrast, when the average grain size of the first inorganic beads isless than the lower limit of the aforementioned range, severe reductionof the efficiency of fine-particle formation (grain size reduction) ofthe pigment particles by the first treatment tends to occur according tothe type and other characteristics of the pigments. When the averagegrain size of the first inorganic beads exceeds the upper limit of theaforementioned range, although the efficiency of fine-particle formation(grain size reduction) of the pigment particles by the first treatmentcan be made relatively excellent, the efficiency of fine-particleformation (grain size reduction) of the pigment particles by the secondtreatment is reduced, and the efficiency of fine-particle formation(fine dispersion) of the pigments is reduced in the fine dispersion stepas a whole.

The amount of the first inorganic beads used is not particularlylimited, but is preferably 100 to 600 parts by weight, and morepreferably 200 to 500 parts by weight with respect to 100 parts byweight of the dispersing-agent-dispersed liquid.

The amount of the pigments added to the dispersing-agent-dispersedliquid is not particularly limited, but is preferably 12 parts by weightor more, and more preferably 18 to 35 parts by weight with respect to100 parts by weight of the dispersing-agent-dispersed liquid.

The first treatment may be performed by stirring using various types ofagitators in a state in which the pigments and the first inorganic beadsare added to the dispersing-agent-dispersed liquid.

Examples of agitators that can be used in the first treatment include aball mill or other media-type dispersing device, a Dispermill or othersingle-shaft or twin-shaft mixer, or the like.

The stirring time (processing time of the first treatment) for which theagitator is used is not particularly limited, but is preferably 10 to120 minutes, and more preferably 15 to 40 minutes. Fine-particleformation (fine dispersion) of the pigments can thereby be efficientlyadvanced without reducing the production properties of the ink.

The speed of the stirring vanes of the agitator in the first treatmentis not particularly limited, but is preferably 1000 to 5000 rpm, andmore preferably 1200 to 3800 rpm. Fine-particle formation (finedispersion) of the pigments can thereby be efficiently advanced withoutreducing the production properties of the ink. Degradation,denaturation, and the like of the thermoplastic resin and othercomponents due to heat and the like can also be reliably prevented.

Second Treatment

A second treatment using second inorganic beads is performed after thefirst treatment. A pigment dispersion is thereby obtained in which thepigment particles are adequately fine dispersed.

The second treatment may be performed in a state in which the firstinorganic beads are included, but the first inorganic beads arepreferably removed prior to the second treatment. Fine-particleformation (fine dispersion) of the pigments in the second treatment canthereby be performed with particularly excellent efficiency. The firstinorganic beads can be easily and reliably removed by filtration or thelike, for example.

The second inorganic beads used in the second treatment preferably havea smaller grain size than the first inorganic beads used in the firsttreatment. The pigments can thereby be adequately formed intofine-particles (fine dispersed) in the ink ultimately obtained,particularly excellent dispersion stability (long-term dispersionstability) of the pigment particles in the ink over a long period oftime can be obtained, and particularly excellent discharge stability ofdroplets can be obtained.

The average grain size of the second inorganic beads is not particularlylimited, but is preferably 0.03 to 0.3 mm, and more preferably 0.05 to0.2 mm. When the average grain size of the second inorganic beads iswithin the aforementioned range, the pigments can be formed intofine-particles (fine dispersed) with particularly excellent efficiencyin the fine dispersion step as a whole. In contrast, when the averagegrain size of the second inorganic beads is less than the lower limit ofthe aforementioned range, severe reduction of the efficiency offine-particle formation (grain size reduction) of the pigment particlesby the second treatment tends to occur according to the type and othercharacteristics of the pigments. When the average grain size of thesecond inorganic beads exceeds the upper limit of the aforementionedrange, fine-particle formation (fine dispersion) of the pigmentparticles can be difficult to adequately advance.

The amount of the second inorganic beads used is not particularlylimited, but is preferably 100 to 600 parts by weight, and morepreferably 200 to 500 parts by weight with respect to 100 parts byweight of the dispersing-agent-dispersed liquid.

The second treatment can be performed using various types of agitators.

Examples of agitators that can be used in the second treatment include aball mill or other media-type dispersing device, a Dispermill or othersingle-shaft or twin-shaft mixer, or the like.

The stirring time (processing time of the second treatment) for whichthe agitator is used is not particularly limited, but is preferably 10to 120 minutes, and more preferably 15 to 40 minutes. Fine-particleformation (fine dispersion) of the pigments can thereby be adequatelyadvanced without reducing the production properties of the ink.

The speed of the stirring vanes of the agitator in the second treatmentis not particularly limited, but is preferably 1000 to 5000 rpm, andmore preferably 1200 to 3800 rpm. Fine-particle formation (finedispersion) of the pigments can thereby be efficiently advanced withoutreducing the production properties of the ink. Degradation,denaturation, and the like of the thermoplastic resin and othercomponents due to heat and the like can also be reliably prevented.

A case was described above in which the fine dispersion process wasperformed in two stages, but three or more stages of processing may alsobe performed. In such a case, the inorganic beads used in the laterstages preferably have a smaller diameter than the inorganic beads usedin the first stages. In other words, the average grain size of theinorganic beads (n^(th) inorganic beads) used in the n^(th) process ispreferably smaller than the average grain size of the inorganic beads((n−1)^(th) inorganic beads) used in the (n−1)^(th) process. Bysatisfying such a relationship, the pigment particles can be formed intofine-particles (fine dispersed) with particularly excellent efficiency,and the diameter of the pigment particles can be reduced in the inkultimately obtained.

In the fine dispersion step (e.g., the first treatment and the secondtreatment), the solvent may be used for dilution or the like, forexample, as needed.

Curable Resin Mixing Step

The pigment dispersion obtained in the fine dispersion step such asdescribed above is mixed with the curable resin material (curable resinmixing step). The ink (color filter ink) is thereby obtained.

The present step is preferably performed in a state in which the secondinorganic beads used in the second treatment have been removed. Thesecond inorganic beads can be easily and reliably removed by filtration,for example.

The present step can be performed using various types of agitators.

Examples of agitators that can be used in the present step include aDispermill or other single-shaft or twin-shaft mixer, or the like.

The stirring time (processing time of the present step) for which theagitator is used is not particularly limited, but is preferably 1 to 60minutes, and more preferably 15 to 40 minutes.

The speed of the stirring vanes of the agitator in the present step isnot particularly limited, but is preferably 1000 to 5000 rpm, and morepreferably 1200 to 3800 rpm.

In the present step, a liquid having a different composition than thesolvent used in the aforementioned step may be added. A ink having thedesired characteristics can thereby be reliably obtained whiledispersion of the dispersing agent in the aforementioned preparatorydispersion step, and fine dispersion of the pigment particles in thefine dispersion step are appropriately performed.

In the present step, at least a portion of the solvent used in theaforementioned step may be removed prior to mixing of the pigmentdispersion and the curable resin material, and after mixing of thepigment dispersion and the curable resin material. The composition ofthe solvent in the preparatory dispersion step and the fine dispersionstep, and the composition of the solvent in the ink ultimately obtainedcan thereby be made to differ from each other. As a result, a ink havingthe desired characteristics can be reliably obtained while dispersion ofthe dispersing agent in the aforementioned preparatory dispersion step,and fine dispersion of the pigment particles in the fine dispersion stepare appropriately performed. The solvent can be removed by placing theliquid to be removed in a reduced-pressure atmosphere, heating, oranother method, for example.

Ink Set

The ink such as that described above is used in the manufacture of acolor filter using an inkjet method. A color filter ordinarily hascolored portions having a plurality of colors (ordinarily, RGBcorresponding to the three primary colors of light) in correlation witha full color display. A plurality of types of ink that correspond to theplurality of colors of colored portions is used in the formation of thecolored portions. In other words, an ink set provided with a pluralityof colors of ink is used in the manufacture of a color filter. In thepresent invention, it is sufficient insofar as a ink such as describedabove is used to form at least one type of colored portion in themanufacturing of a color filter, but the ink is preferably used to formall of the colors of colored portions.

Image Display Device

Preferred embodiments of the liquid crystal display device, which is animage display device (electrooptic device) having the color filter 1,will next be described.

FIG. 8 is a cross-sectional view showing a preferred embodiment of theliquid crystal display device. As shown in the diagram, the liquidcrystal display device 60 has a color filter 1, a substrate (opposingsubstrate) 66 arranged on the surface on which the colored portions 12of the color filter 1 are disposed, a liquid crystal layer 62 composedof a liquid crystal sealed in the gaps between the color filter 1 andthe substrate 66, a polarizing plate 67 disposed on the surface (lowerside in FIG. 8) opposite from the surface that faces the liquid crystallayer 62 of the substrate 11 of the color filter 1, and a polarizingplate 68 disposed on the side (upper side in FIG. 8) opposite from thesurface that faces liquid crystal layer 62 of the substrate 66. A sharedelectrode 61 is disposed on the surface (the surface opposite from thesurface facing the substrate 11 of the colored portions 12 and thepartition wall 13) on which the colored portions 12 and the partitionwall 13 of the color filter 1 are disposed. Pixel electrodes 65 aredisposed in the form of a matrix in positions that correspond to thecolored portions 12 of the color filter 1 on the substrate (opposingsubstrate) 66, facing the liquid crystal layer 62 and color filter 1. Analignment film 64 is disposed between the shared electrode 61 and theliquid crystal layer 62, and an alignment film 63 is disposed betweenthe substrate 66 (pixel electrodes 65) and the liquid crystal layer 62.

The substrate 66 is a substrate having optical transparency with respectto visible light, and is a glass substrate, for example.

The shared electrode 61 and the pixel electrodes 65 are composed of amaterial having optical transparency with respect to visible light, andare ITO or the like, for example.

Although not depicted in the diagram, a plurality of switching elements(e.g., TFT: thin film transistors) is disposed so as to correspond tothe pixel electrodes 65. The pixel electrodes 65 corresponding to thecolored portions 12 can be used to control the transmission propertiesof light in areas that correspond to the colored portions 12 (pixelelectrodes 65) by controlling the state of the voltage applied betweenthe shared electrode 61 and the pixel electrodes.

In the liquid crystal display device 60, light emitted from thebacklight, which is not depicted, is incident from the polarizing plate68 side (the upper side in FIG. 8). The light that passes through theliquid crystal layer 62 and enters the colored portions 12 (12A, 12B,12C) of the color filter 1 is emitted from the polarizing plate 67(lower side of FIG. 8) as light having a color that corresponds to thecolored portions 12 (12A, 12B, 12C).

As described above, since the colored portions 12 are formed using thecolor filter manufacturing method of the present invention, color mixingbetween adjacent colored portions 12 is prevented. As a result, theliquid crystal display device 60 has excellent color reproductionproperties.

Electronic Device

A liquid crystal display device or another image display device(electrooptic device) 1000 having a color filter 1 such as thatdescribed above can be used in a display unit of a variety of electronicequipment.

FIG. 9 is a perspective view showing the configuration of a mobile (ornotebook) personal computer to which the electronic equipment of thepresent invention has been applied.

In the diagram, a personal computer 1100 is composed of a main unit 1104provided with a keyboard 1102, and a display unit 1106. The display unit1106 is rotatably supported by the main unit 1104 via a hinge structure.

In the personal computer 1100, the display unit 1106 is provided with animage display device 1000.

FIG. 10 is a perspective view showing the configuration of a portabletelephone (including PHS) to which the electronic device of the presentinvention has been applied.

In the diagram, the portable telephone 1200 has a plurality of operatingbuttons 1202, an earpiece 1204, and a mouthpiece 1206, as well as animage display device 1000 provided to the display unit.

FIG. 11 is a perspective view showing the configuration of a digitalstill camera in which the electronic device of the present invention hasbeen applied. In the diagram, connection to external apparatuses isdisplayed in a simplified manner.

In this case, an ordinary camera exposes a silver-salt photography filmto the optical image of a photographed object, but in contrast, adigital still camera 1300 photoelectrically converts the optical imageof a photographed image and generates an imaging signal (image signal)with the aid of a CCD (Charge Coupled Device) or another imagingelement.

An image display device 1000 is disposed in the display portion on theback surface of a case (body) 1302 in the digital still camera 1300, isconfigured to perform display operation on the basis of a pickup signalfrom the CCD, and functions as a finder for displaying the photographedobject as an electronic image.

A circuit board 1308 is disposed inside the case. The circuit board 1308has a memory that can store (record) the imaging signal.

A photo-detection unit 1304 that includes an optical lens (imagingoptical system), a CCD, and the like is disposed on the front surfaceside (back surface side in the configuration of the diagram) of the case1302.

A photographer confirms the image of the object to be photographeddisplayed on the display unit, and the imaging signal of the CCD when ashutter button 1306 is pressed is transferred and stored in the memoryof the circuit board 1308.

In the digital still camera 1300, a video signal output terminal 1312and a data communication I/O terminal 1314 are disposed on the sidesurface of the case 1302. A television monitor 1430 is connected to thevideo signal output terminal 1312 as required, and a personal computer1440 is connected to the data communication I/O terminal 1314 asrequired, as shown in the diagram. An imaging signal stored in thememory of the circuit board 1308 is configured to be outputted by aprescribed operation to the television monitor 1430 and the personalcomputer 1440.

The electronic device of the present invention may be applied to theabove-described personal computer (mobile personal computer), portabletelephone, and digital still camera, and other examples includetelevisions (e.g., liquid crystal display devices), video cameras, viewfinder-type and direct-view monitor-type video tape recorders, laptoppersonal computers, car navigation devices, pagers, electronicassistants (including those with a communication function), electronicdictionaries, calculators, electronic game devices, word processors,work stations, videophones, security television monitors, electronicbinoculars, POS terminals, apparatuses having a touch panel (e.g., cashdispensers for financial institutions, and automatic ticketingmachines), medical equipment (e.g., electronic thermometers,sphygmomanometers, blood glucose sensors, electrocardiograph displaydevices, ultrasound diagnostic devices, and endoscopic display devices),fish finders, various measuring apparatuses, instruments (e.g.,instruments in vehicles, aircraft, and ships), flight simulators, andvarious other monitors, and projectors, and other projection displaydevices. Among these, televisions have display units that are tending tobecome markedly larger in recent years, but in electronic devices havingsuch a large display unit (e.g., a display unit having a diagonal lengthof 80 cm or more), color mixing occurs between adjacent coloredportions, and problems in color reproduction properties occur readilywhen a color filter manufactured using a conventional color filtermanufacturing method is used. However, the occurrence of such problemscan be reliably prevented through the use of the present invention. Inother words, the effect of the present invention is more markedlydemonstrated when application is made to an electronic device having alarge display unit such as that described above.

The present invention above was described based on preferredembodiments, but the present invention is not limited to theseembodiments.

For example, in the embodiments described above, the landing prohibitionregion was described as being provided to both edges of the cell, butthis configuration is not limiting, and a landing prohibition region maybe provided to only one edge of a cell.

The ink is also not limited to being obtained by a method such asdescribed above.

It is also possible to substitute or to add as another configuration theparts constituting a color filter, image display device, and electronicdevice with any part that demonstrates the same function.

EXAMPLES

Next, specific examples of the present invention will be described.

1. Synthesis Of Polymer (Preparation Of Polymer Solution) SynthesisExample 1

As the medium (solvent), 37.6 parts by weight of 1,3-butylene glycoldiacetate was placed in a 1-L reaction container provided with anagitator, a reflux condenser, a dropping funnel, a nitrogen introductiontube, and a temperature gauge, and heated to 90° C. Next, 2 parts byweight of 2,2′-azobis(isobutyronitrile) (AIBN) and 3 parts by weight1,3-butylene glycol diacetate (solvent) were added, and a solution inwhich 27 parts by weight of (3,4-epoxycyclohexyl)methyl methacrylate(product name: Cyclomer M100, manufactured by Daicel ChemicalIndustries), 1.5 parts by weight of2(0-[1′-methylpropylideneamino]carboxyamino)ethyl methacrylate (productname: MOI-BM, manufactured by Showa Denko), and 1.5 parts by weight of2-hydroxyethyl methacrylate (HEMA) were admixed was dropped over about 4hours using a dropping pump. Also, a solution (polymerization initiatorsolution) in which 5 parts by weight of dimethyl2,2′-azobis(isobutyrate) (product name V-601, manufactured by Wako PureChemical Industries) as the polymerization initiator were dissolved in20 parts by weight of 1,3-butylene glycol diacetate (medium) was droppedover about 4 hours using a separate dropping pump. After the dropping ofthe polymerization initiator solution was completed, 0.2 part by weightof AIBN and 1 part by weight of 1,3-butylene glycol diacetate (medium)was added and held for about 2 hours at about the same temperature,after which 0.2 part by weight of AIBN and 1 part by weight of1,3-butylene glycol diacetate (medium) was added and held for about 2hours at about the same temperature, and then cooled to room temperatureto obtain a polymer solution A1 containing a polymer A.

Synthesis Example 2

The same operation as synthesis example 1 described above was carriedout, except that the type of monomer components, usage amount, and typeof medium (solvent) used in the synthesis of the polymer (preparation ofthe polymer solution) were varied in the manner shown in Table 1. As aresult, a polymer solution A2 containing a polymer A was obtained.

Synthesis Example 3

The same operation as synthesis example 1 described above was carriedout, except that 30 parts by weight of y-methacryloxypropyltrimethoxysilane (product name: SZ6030, manufactured by Dow CorningToray) was used in place of (3,4-epoxycyclohexyl)methyl methacrylate(product name: Cyclomer M100, manufactured by Daicel ChemicalIndustries), 2-(0-[1′-methylpropylideneamino]carboxyamino)methacrylate(product name: MOI-BM, manufactured by Showa Denko), and 2-hydroxyethylmethacrylate (HEMA). As a result, a polymer solution B1 (homopolymer)containing a polymer B was obtained.

Synthesis Example 4

The same operation as synthesis example 3 described above was carriedout, except that the type of monomer components, usage amount, and typeof medium (solvent) used in the synthesis of the polymer (preparation ofthe polymer solution) were varied in the manner shown in Table 1. As aresult, a polymer solution B2 containing a polymer B was obtained.

Synthesis Example 5

The same operation as synthesis example 1 described above was carriedout, except that 30 parts by weight of 1H,1H,5H-octafluoropentylmethacrylate (product name: Biscoat 8FM, manufactured by Osaka OrganicChemical Industry) was used in place of (3,4-epoxycyclohexyl)methylmethacrylate (product name: Cyclomer M100, manufactured by DaicelChemical Industries),2-(0-[1′-methylpropylideneamino]carboxyamino)methacrylate (product name:MOI-BM, manufactured by Showa Denko), and 2-hydroxyethyl methacrylate(HEMA). As a result, a polymer solution C1 (homopolymer solution)containing a polymer C was obtained.

Synthesis Example 6

The same operation as synthesis example 5 described above was carriedout, except that the type of monomer components, usage amount, and typeof medium (solvent) used in the synthesis of the polymer (preparation ofthe polymer solution) were varied in the manner shown in Table 1. As aresult, a polymer solution C2 containing a polymer C was obtained.

The type of material and usage amount (composition of the polymersynthesized in synthesis examples 1 to 6) used in the synthesis of thepolymers (preparation of the polymer solutions) in the synthesis example1 to 6 are summarized in Table 1. In the table, “S” refers to a medium(solvent), and more particularly “S1” refers 1,3-butylene glycoldiacetate, “S2” refers to diethylene glycol monobutyl ether acetate,“V-601” refers to dimethyl 2,2′-azobis(isobutyrate), “AIBN” refers to2,2′-azobis(isobutyronitrile), “a1” refers to(3,4-epoxycyclohexyl)methyl methacrylate (Cyclomer M100), “a2” refers to2-(0-[1′-methylpropylideneamino]carboxyamino)ethyl methacrylate(MOI-BM), “a3” refers to 2-hydroxyethyl methacrylate (HEMA), “b1” refersto γ-methacryloxypropyl trimethoxysilane (SZ6030), “b2” refers to ethylmethacrylate, “c1-1” refers to 1H,1H,5H-octafluoropentyl methacrylate(Biscoat 8FM), “c1-2” refers to 1,2,3,4,5-pentafluorostyrene, and “c2”refers to cyclohexyl methacrylate. Also shown in the table are theweight-average molecular weights Mw of the polymers that constitute thepolymer solutions.

TABLE 1 COMPONENTS (PARTS BY WEIGHT) MONOMER COMPONENT SOLVENT (S)POLYMER a1 a2 a3 a4 b1 b2 c1-1 c1-2 c2-2 M V-601 AIBN COMPOSITION MwPOLYMER 27 1.5 1.5 — — — — — — 62.6 5 2.4 S1 2700 SOLUTION A1 POLYMER 251 2 2 — — — — — 62.6 5 2.4 S2 2800 SOLUTION A2 POLYMER — — — — 30 — — —— 62.6 5 2.4 S1 2800 SOLUTION B1 POLYMER — — — — 26 4 — — — 62.6 5 2.4S2 2800 SOLUTION B2 POLYMER — — — — — — 30 — — 62.6 5 2.4 S1 2800SOLUTION C1 POLYMER — — — — — — — 28 2 62.6 5 2.4 S2 2800 SOLUTION C2

2. Preparation of Color Filter Ink (Ink Set) Ink Set 1

Added to an agitator (single-shaft mixer) having a capacity of 400 ccwere 5.04 g (14 parts by weight) of Disperbyk 111 as a dispersing agent,28.07 g (78 parts by weight) of Disperbyk 166 as a dispersing agent,19.43 g (54 parts by weight) of SPCN-17X (manufactured by ShowaHighpolymer) as a thermoplastic resin, and 91.05 g (253 parts by weight)of 1,3-butylene glycol diacetate as a solvent, and adispersing-agent-dispersed liquid was obtained by stirring the mixturefor 10 minutes in a Dispermill and performing preparatory dispersion(preparatory dispersion step). The speed of the stirring vanes of theagitator at this time was set to 2000 rpm.

Pigments were then added as described below to thedispersing-agent-dispersed liquid obtained by the preparatory dispersionstep, inorganic beads were added in multiple stages, and the finedispersion step of performing the fine dispersion process was performed.

First, 35.99 g (100 parts by weight) of pigments were added at once tothe obtained dispersing-agent-dispersed liquid, and the mixture wasstirred for 10 minutes. At this time, the speed of the stirring vanes ofthe agitator was set to 2000 rpm. The mixture used as the pigmentsincluded 25.85 g of a mixture of C. I. Pigment Red 254 and a pigmentderivative indicated by Formula (5), 7.60 g of a mixture of C. I.Pigment Red 177 and a pigment derivative indicated by Formula (4), and3.55 g of a powdered sulfonated pigment derivative having the chemicalstructure indicated by Formula (6). At this time, the mixture of thepigments and the dispersing-agent-dispersed liquid was diluted by1,3-butylene glycol diacetate as a first liquid medium to give a pigmentcontent ratio of 16 wt %.

In Formula (5), n is an integer from 1 to 4.

In Formula (4), n is an integer from 1 to 4.

In Formula (6), n is an integer from 1 to 5.

Next, inorganic beads (first inorganic beads: zirconia beads; “TorayCeram grinding balls” (trade name); manufactured by Toray) having anaverage grain size of 0.8 mm were then added, the mixture was stirredfor 30 minutes at room temperature, and the first stage of dispersionprocessing (first treatment) was performed. At this time, the speed ofthe stirring vanes of the agitator was set to 2000 rpm.

The inorganic beads (first inorganic beads) were then removed byfiltration using a filter (“PALL HDCII Membrane Filter”; manufactured byPALL), after which inorganic beads (second inorganic beads: zirconiabeads; “Toray Ceram grinding balls” (trade name); manufactured by Toray)having an average grain size of 0.1 mm were added, the mixture wasfurther stirred for 30 minutes, and the second stage of dispersionprocessing (second treatment) was performed. At this time, the speed ofthe stirring vanes of the agitator was set to 2000 rpm. The mixture wasalso diluted by 1,3-butylene glycol diacetate as a first liquid medium.

The inorganic beads (second inorganic beads) were then removed byfiltration using a filter (“PALL HDCII Membrane Filter”; manufactured byPALL), and a pigment dispersion was obtained.

The pigment dispersion obtained as described above, the polymer solutionA1, the polymer solution B1, the polymer solution C1, and 1,3-butyleneglycol diacetate as a solvent were then mixed. The present step wasperformed by placing the abovementioned pigment dispersion, polymersolution A1, polymer solution B1, and polymer solution C1 in a 400 ccagitator (single-shaft mixer) and stirring the mixture for 10 minutes ina Dispermill. At this time, the speed of the stirring vanes of theagitator was set to 2000 rpm. The desired red color filter ink (R ink)was thereby obtained. The pigment content ratio of the R ink at thistime was 7.3 wt %.

A green color filter ink (G ink) and a blue color filter ink (B ink)were prepared in the same manner as the red color filter ink describedabove, except that the type of pigment and the usage amount of eachcomponent were varied. A first ink set corresponding to the R ink andcomposed of the three colors R, G, B was thereby obtained. The averagegrain size of the pigment constituting the R ink, the average grain sizeof the pigment constituting the G ink, and the average grain size of thepigment constituting the B ink were 70 nm, 70 nm, and 70 nm,respectively. Also, C. I. Pigment Green 58 and a powdered sulfonatedpigment derivative having the chemical structure indicated by Formula(3) were used as the G ink pigments, and the content ratio of pigmentsin the final G ink was 10.1 wt %. Also, C. I. Pigment Blue 15:6 was usedas the pigment of the B ink, and the content ratio of pigment in thefinal B ink was 4.9 wt %.

Ink Sets 2 and 3

Color filter ink sets were prepared in the same manner as Ink Set 1,except that the types and usage amounts of materials used to prepare thecolor inks were varied as shown in Table 2.

Table 2 also shows the compositions and characteristics of the ink sets.

In the table, C. I. Pigment Red 254 is referred to as “PR254, C. I.Pigment Red 177 is referred to as “PR177,” C. I. Pigment Green 58 isreferred to as “PG58,” C. I. Pigment Green 36 is referred to as “PG36,”C. I. Pigment Blue 15:6 is referred to as “PB15:6,” C. I. Pigment Yellow150 is referred to as “PY150,” the mixture of C. I. Pigment Red 254 andthe pigment derivative indicated by Formula (5) is referred to as“PR254D,” the mixture of C. I. Pigment Red 177 and the pigmentderivative indicated by Formula (4) is referred to as “PR177D,”1,3-butylene glycol diacetate is referred to as “S1,” diethylene glycolmonobutyl ether acetate is referred to as “S2,” Disperbyk 111 isreferred to as “DA1,” Disperbyk 166 is referred to as “DA2,” andSPCN-17X is referred to as “DR1.”

In the uncured resin material column in Table 2, the polymer included inthe polymer solution A1 is indicated as A1. In the same manner, thepolymers included in the polymer solutions A2 to A9, B1 to B5, and C1 toC3 are referred to as A2 to A9, B1 to B5, and C1 to C3, respectively.The viscosities were measured using an E-type viscometer (e.g., RE-01manufactured by Toki Sangyo) at 25° C. in accordance with JIS Z8809.

TABLE 2 COLOR INK COMPOSITION THERMOPLASTIC CURABLE RESIN DISPERSINGPIGMENT RESIN MATERIAL AGENT CONTENT CONTENT CONTENT CONTENT RATIO RATIORATIO RATIO TYPE (wt %) TYPE (wt %) TYPE (wt %) TYPE (wt %) INK SET 1 RINK PR177D/PR254D/SPD 5.1/1.5/0.7 DR1 3.9 A1/B1/C1 0.8/0.8/0.4 DA1 1.0 GINK PG58/SPD 9.1/1.0 DR1 8.0 A1/B1/C1 0.8/0.8/0.4 DA1 1.2 B INK PB15:64.9 DR1 4.3 A1/B1/C1 0.8/0.8/0.4 DA1 0.7 INK SET 2 R INKPR177D/PR254D/SPD 5.1/1.5/0.7 DR1 3.9 A2/B2/C2 0.8/0.8/0.4 DA1 1.0 G INKPG58/SPD 9.1/1.0 DR1 8.0 A7/B6/C3 0.8/0.8/0.4 DA1 1.2 B INK PB15:6 4.9DR1 4.3 A7/B6/C3 0.8/0.8/0.4 DA1 0.7 INK SET 3 R INK PR177D/PR254D/SPD5.1/1.5/0.7 DR1 3.9 A1/B1 1.1/1.0 DA1 1.0 G INK PG58/SPD 9.1/1.0 DR1 8.0A1/B1 1.1/1.0 DA1 1.2 B INK PB15:6 4.9 DR1 4.3 A1/B1 1.1/1.0 DA1 0.7COLOR INK COMPOSITION DISPERSING AGENT SOLVENT CONTENT CONTENT CURINGRATIO RATIO AGENT VISCOSITY TYPE (wt %) TYPE (wt %) (wt %) (mPa · s) INKSET 1 R INK DA2 5.7 S1 80.1 — 10.1 G INK DA2 3.6 S1 75.1 — 8.3 B INK DA22.1 S1 86.0 — 8.4 INK SET 2 R INK DA2 5.7 S2 80.1 — 10.0 G INK DA2 3.6S2 75.1 — 8.9 B INK DA2 2.1 S2 86.0 — 9.0 INK SET 3 R INK DA2 5.7 S380.0 — 10.2 G INK DA2 3.6 S3 75.0 — 8.0 B INK DA2 2.1 S3 85.9 — 7.6

3. Manufacture of Color Filters Example 1

A color filter was manufactured as described below using the ink set 1obtained as described above.

First, a substrate (G5 size: 1100×1300 mm) composed of soda glass onwhich a silica (SiO₂) film for preventing elution of the sodium ions wasformed on the two sides was prepared and washed.

Next, a radiation-sensitive composition for forming a partition wallcontaining carbon black was applied to the entire surface of one of thesurfaces of the washed substrate to form a coated film.

Next, a prebaking treatment was performed at a heating temperature of110° C. and a heating time of 120 seconds.

The substrate was thereafter irradiated via a photomask, subjected topost exposure baking (PEB), subsequently developed using an alkalidevelopment fluid, and then subjected to a post baking treatment tothereby form a partition wall. PEB was carried out at a heatingtemperature of 110° C., a heating time of 120 seconds, and anirradiation intensity of 150 mJ/cm². The development treatment time wasset to 60 seconds. The post baking treatment was carried out at aheating temperature of 150° C. for a heating time of 5 minutes. Thethickness of the partition wall thus formed was 2.1 μm. The width L₃ inthe movement direction (Y-axis direction) of the cell substrate withrespect to the droplet discharge head was 100 μm.

Next, the ink was discharged into the cells as areas surrounded by thepartition wall by using a droplet discharge device such as that shown inFIGS. 3 to 6. In this case, three color filter inks were used. A dropletdischarge head was used in which the nozzle plate had been bonded usingan epoxy adhesive (AE-40, manufactured by Ajinomoto Fine-Techno). Thedroplets were set so as not to land in the regions (landing prohibitionregions) at a width L₁ (20.0 μm) from both edges of the cells in thedirection (Y-axis direction) of movement of the substrate relative tothe droplet discharge head. The average diameter L₂ of the dropletsdischarged from the droplet discharge device was set to 5.0 μm. Themovement speed of the substrate relative to the droplet discharge headwas set to 300 mm/second.

Thereafter, heat treatment is carried out for 10 minutes at 100° C. on ahot plate, and heat treatment was then carried out for one hour in anoven at 200° C., whereby three colored portions were formed. A colorfilter such as that shown in FIG. 1 was thereby obtained.

Examples 2 through 7

Color filters were manufactured in the same manner as in Example 1,except that the cell sizes were changed as shown in Table 3, and thewidth L₁ of the landing prohibition regions, the average diameter L₂ ofthe droplets, and the movement speed of the substrate relative to thedroplet discharge head were also varied as shown in Table 3.

Examples 8 and 9

Color filters were manufactured in the same manner as in Example 1,except that the ink sets 1 were changed to the ink sets shown in Table3.

Comparative Examples 1 and 2

Color filters were manufactured in the same manner as in Example 1,except that the cell width L₃ was changed as shown in Table 3, and thewidth L₁ of the landing prohibition regions, the average diameter L₂ ofthe droplets, and the movement speed of the substrate relative to thedroplet discharge head were also varied as shown in Table 3.

Table 3 also shows the cell width and height, and the settings of thedroplet discharge device in the examples and comparative examples. Thecontact angle of the ink with respect to the substrate was also measuredin accordance with JIS K 3257 and shown in Table 3.

TABLE 3 DROPLET DISCHARGE DEVICE SETTINGS SUBSTRATE SUBSTRATEPROHIBITION AVERAGE CONTACT ANGLE CELL CELL MOVEMENT REGION DROPLETBETWEEN WIDTH L3 HEIGHT SPEED WIDTH L1 DIAMETER L2 SUBSTRATE AND INK(μm) (nm) (mm/sec) (μm) (μm) L1/L2 L1/L3 R INK (°) G INK (°) B INK (°)EXAMPLE 1 100.0 2.1 300.0 20.0 5.0 4.0 0.2 53 50 51 EXAMPLE 2 100.0 2.1300.0 8.3 16.6 0.5 0.083 53 50 51 EXAMPLE 3 100.0 2.1 300.0 20.0 4.4 4.50.2 53 50 51 EXAMPLE 4 100.0 2.1 300.0 2.5 0.63 4.0 0.025 53 50 51EXAMPLE 5 50.0 2.1 300.0 25.0 12.5 2.0 0.5 53 50 51 EXAMPLE 6 50.0 2.1300.0 5.0 5.0 1.0 0.1 53 50 51 EXAMPLE 7 40.0 2.1 300.0 12.5 5.0 2.50.31 53 50 51 EXAMPLE 8 350.0 1.4 300.0 20.0 5.0 4.0 0.057 53 50 51EXAMPLE 9 350.0 2.6 300.0 20.0 5.0 4.0 0.057 53 50 51 COMPARA- 100.0 2.1300.0 70.0 14.0 5.0 0.7 53 50 51 TIVE EXAMPLE 1 COMPARA- 350.0 2.1 300.08.0 20.0 0.4 0.023 53 50 51 TIVE EXAMPLE 2

4. Evaluation of Color Filters

The color filters obtained in the manner described above were evaluatedin the manner described below

4-1. Evaluation Of Color Reproduction Properties

A liquid crystal display device such as shown in FIG. 8 was manufacturedusing the color filters manufactured in the examples and comparativeexamples.

The transmission spectrum was measured by a spectrophotometer (MCPD3000, manufactured by Otsuka Electronics) for the obtained liquidcrystal display devices using a standard C light source in a state ofred monochromatic display, green monochromatic display, and bluemonochromatic display. The hue (R(xy), G(xy), B(xy)) according to an xydisplay system was calculated, the NTSC ratio was computed, andevaluation was performed according to the three ranges described below.A higher NTSC ratio can be considered to indicate higher colorreproduction properties.

A: 100NTSC ratio is 80% or higher.

B: NTSC ratio is 73% or higher and less than 80%.

C: NTSC ratio is less than 73%.

D: There is significant fluctuation per pixel due to light leakage andthe like, and measurement is meaningless.

4-2. Evaluation of Color Mixing

An arbitrary 1000 pixels of the color filters obtained in the examplesand working examples were observed by a microscope, and color mixing wasevaluated according to the criteria below.

A: No color mixing or crossover of ink onto the partition wall wasobserved.

B: Color mixing was not observed, but crossover of ink onto thepartition wall was observed, and the occurrence thereof was 1% or less.

C: Color mixing was not observed, but crossover of ink onto thepartition wall was observed, and the occurrence thereof was higher than1%, and 5% or lower.

D: Color mixing was observed, or the occurrence of ink crossover ontothe partition wall was higher than 5%.

4-3. Evaluation of Light Leakage

Liquid crystal display devices such as shown in FIG. 8 were assembledusing ten color filters from each of the examples and comparativeexamples.

Visual observation was performed using the liquid crystal displaydevices in a dark room in a state of red monochromatic display, greenmonochromatic display, blue monochromatic display, and whitemonochromatic display, and the occurrence of light leakage (white spots,luminescent spots) was evaluated according to the five ranges shownbelow.

A: There was no color filter in which light leakage (white spots,luminescent spots) occurred.

B: Light leakage (white spots, luminescent spots) was observed in 1 to 2color filters.

C: Light leakage (white spots, luminescent spots) was observed in 3 to 5color filters.

D: Light leakage (white spots, luminescent spots) was observed in 6 to 9color filters.

E: Light leakage (white spots, luminescent spots) was observed in 10color filters.

These results are shown in Table 4.

TABLE 4 EVALUATION OF EVAL- COLOR EVALUATION UATION REPRODUCTION OFCOLOR OF LIGHT PROPERTIES MIXING LEAKAGE EXAMPLE 1 A A A EXAMPLE 2 A B AEXAMPLE 3 A A B EXAMPLE 4 A A A EXAMPLE 5 A A A EXAMPLE 6 A A A EXAMPLE7 A A A EXAMPLE 8 A A A EXAMPLE 9 A A A COMPARATIVE D A E EXAMPLE 1COMPARATIVE D D C EXAMPLE 2

As is apparent from Table 4, color mixing was prevented, and excellentcolor reproduction properties were obtained in the color filtersmanufactured by the manufacturing method of the present invention. Therewas also no light leakage. In contrast, satisfactory results were notobtained in the color filters of the comparative examples.

The similar results as described above were also obtained when acommercially available liquid crystal television was disassembled, theliquid crystal display device unit was replaced by a unit manufacturedas described above, and the same evaluations as described above wereperformed.

General Interpretation of Terms

In understanding the scope of the present invention, the term“comprising” and its derivatives, as used herein, are intended to beopen ended terms that specify the presence of the stated features,elements, components, groups, integers, and/or steps, but do not excludethe presence of other unstated features, elements, components, groups,integers and/or steps. The foregoing also applies to words havingsimilar meanings such as the terms, “including”, “having” and theirderivatives. Also, the terms “part,” “section,” “portion,” “member” or“element” when used in the singular can have the dual meaning of asingle part or a plurality of parts. Finally, terms of degree such as“substantially”, “about” and “approximately” as used herein mean areasonable amount of deviation of the modified term such that the endresult is not significantly changed. For example, these terms can beconstrued as including a deviation of at least ±5% of the modified termif this deviation would not negate the meaning of the word it modifies.

While only selected embodiments have been chosen to illustrate thepresent invention, it will be apparent to those skilled in the art fromthis disclosure that various changes and modifications can be madeherein without departing from the scope of the invention as defined inthe appended claims. Furthermore, the foregoing descriptions of theembodiments according to the present invention are provided forillustration only, and not for the purpose of limiting the invention asdefined by the appended claims and their equivalents.

1. A color filter manufacturing method comprising: discharging dropletsof an ink from a droplet discharge head into a plurality of cells formedon a substrate while moving the substrate with respect to the dropletdischarge head; and curing the ink discharged in the cells to form acolored portion within each of the cells, the discharging of thedroplets including prohibiting landing of the droplets in a landingprohibition region formed at a predetermined width from edges of each ofthe cells in a movement direction of the substrate with respect to thedroplet discharge head, with the landing prohibition region beingarranged so that a relationship 0.5≦L₁/L₂≦4.5 is satisfied, wherein avalue L₁ (μm) indicates a width of the landing prohibition region and avalue L₂ (μm) indicates an average diameter of the droplets of the ink.2. The color filter manufacturing method according to claim 1, whereinthe landing prohibition region is arranged such that a relationship0.025≦L₁/L₃≦0.5 is satisfied, wherein a value L₃ (μm) indicates a widthof each of the cells in the movement direction of the substrate withrespect to the droplet discharge head.
 3. The color filter manufacturingmethod according to claim 1, wherein the width L₁ of the landingprohibition region is 3.0 to 50.0 μm.
 4. The color filter manufacturingmethod according to claim 1, wherein the ink has a viscosity of 13 mPa·sor less at 25° C.
 5. The color filter manufacturing method according toclaim 1, wherein the droplets have a contact angle of 60° or less withrespect to the substrate.
 6. The color filter manufacturing methodaccording to claim 1, wherein the discharging of the droplets includesmoving the substrate with respect to the droplet discharge head at aspeed of 30 to 400 mm/second.
 7. The color filter manufacturing methodaccording to claim 1, wherein the substrate includes a partition wallprovided between an adjacent pair of the cells with the partition wallhaving a height of 1.4 to 2.6 μm.
 8. The color filter manufacturingmethod according to claim 1, wherein the ink includes at least acolorant, a resin material, and a solvent with the resin materialincluding a first polymer containing at least a first epoxy-containingvinyl monomer as a monomer component.
 9. The color filter manufacturingmethod according to claim 8, wherein the first polymer is a copolymerhaving the first epoxy-containing vinyl monomer and a second vinylmonomer as monomer components, the second vinyl monomer having anisocyanate group or a block isocyanate group in which an isocyanategroup is protected by a protective group.
 10. The color filtermanufacturing method according to claim 8, wherein the first polymer isa copolymer having the first epoxy-containing vinyl monomer and a thirdvinyl monomer as monomer components, the third vinyl monomer having ahydroxyl group.
 11. The color filter manufacturing method according toclaim 8, wherein the resin material further includes a second polymercontaining at least an alkoxysilyl-containing vinyl monomer representedby a chemical formula (1) below as a monomer component,

wherein, in the chemical formula (1), R¹ represents a hydrogen atom or aC₁₋₇ alkyl group, E represents a single bond hydrocarbon group or abivalent hydrocarbon group, R² represents a C₁₋₆ alkyl group or a C₁₋₆alkoxyl group, R³ represents a C₁₋₆ alkyl group or a C₁₋₆ alkoxyl group,R⁴ represents a C₁₋₆ alkyl group, a value x is 0 or 1, and a value y isan integer from 1 to
 10. 12. The color filter manufacturing methodaccording to claim 8, wherein the resin material when uncured furtherincludes a third polymer containing at least a fluoroalkyl- orfluoroaryl-containing vinyl monomer represented by a chemical formula(2) below as a monomer component,

wherein, in the chemical formula (2), R⁵ represents a hydrogen atom or aC₁₋₇ alkyl group, D represents a single bond hydrocarbon group, abivalent hydrocarbon group, or a bivalent hydrocarbon group containing ahetero atom, Rf represents a C₁₋₂₀ fluoroalkyl group or fluoroarylgroup, and a value z is 0 or
 1. 13. A color filter manufactured usingthe color filter manufacturing method according to claim
 1. 14. An imagedisplay device having the color filter according to claim
 13. 15. Anelectronic device having the image display device according to claim 14.